85/15 Zn-Al Wire 99.99% Purity For Thermal Spray ASTM B833
Product Specifications
| Parameter | Specification |
|---|---|
| Alloy | 85% Zn ± 1% + 15% Al ± 1% (by weight) |
| Zinc Purity | SHG Zinc – 99.99% min (ASTM B6) |
| Aluminum Purity | Primary Ingot – 99.7% min (EN 576) |
| Standards | ASTM B833-20, ISO 14919, DIN 14919:2001, EN 1179 Z1, EN 573-3 |
| Wire Diameter | Ø1.6 mm (1/16") / Ø3.2 mm (1/8") |
| Process | Electric Arc Spray • Flame Spray (wire-fed) |
| Typical Coating | 80–200 µm per pass; up to 500 µm multi-pass |
| Packaging | Layer-wound spools (10–15 kg); drums for bulk projects |
| Certificate | SGS Mill Test Report per production batch |
Chemical Composition
Produced from virgin ingots only - no secondary or recycled scrap - ensuring batch-to-batch consistency and full traceability from smelter to spool.
| Element | Spec (wt%) | Typical |
|---|---|---|
| Zinc (Zn) | 84.0 – 86.0 | ~85.0 |
| Aluminum (Al) | 14.0 – 16.0 | ~15.0 |
| Lead (Pb) | ≤ 0.003 | < 0.002 |
| Cadmium (Cd) | ≤ 0.002 | < 0.001 |
| Iron (Fe) | ≤ 0.015 | < 0.008 |
| Copper (Cu) | ≤ 0.001 | < 0.001 |
| Silicon (Si) | ≤ 0.010 | < 0.005 |
| Others (each) | ≤ 0.01 | < 0.01 |
| Zn + Al Total | ≥ 99.95 | ~99.98 |
Why 85/15 Zn-Al? The Science of Dual-Phase Protection
The 85% zinc / 15% aluminum ratio was not chosen by chance - it is the result of decades of study on the electrochemical behavior of Zn-Al alloys for thermal spray coatings. At this precise ratio, the coating delivers two complementary protection mechanisms simultaneously:
- Sacrificial (Cathodic) Protection from Zinc. Zinc corrodes preferentially to steel in the galvanic series, providing active protection at scratches, pinholes, and cut edges - even when the coating is damaged. This "throwing power" is zinc's signature advantage.
- Passive Barrier Protection from Aluminum. Aluminum forms a stable, self-repairing oxide layer (Al₂O₃) that blocks moisture, chlorides, and oxygen - significantly improving performance in aggressive marine and industrial environments.
Research has shown that above ~28% aluminum, the coating behaves essentially as pure aluminum - losing the cathodic reach of zinc. At 15%, the 85/15 composition optimally balances both mechanisms, producing a dense dual-phase microstructure that field tests have proven to outperform either pure zinc or pure aluminum alone.
"The 85/15 Zn/Al alloy produces a coating with the best anti-corrosion characteristics of both zinc and aluminum - combining zinc's galvanic protection with aluminum's oxidative passivation." - Platt Brothers, Thermal Spray Wire Technical Reference
Application Parameters (Electric Arc Spray)
| Parameter | Recommended Range |
|---|---|
| Voltage | 28–32 V |
| Current | 100–250 A |
| Spray Distance | 150–250 mm |
| Atomizing Air | 4–6 bar (60–90 psi) |
| Deposition Efficiency | 60–75% |
| Bond Strength | > 10 MPa (ASTM C633) |
Alloy Comparison: Which Wire for Your Project?
| Property | Pure Zn (99.995%) | 85/15 Zn-Al ★ | Pure Al (99.7%) |
|---|---|---|---|
| Cathodic Protection | ⭐⭐⭐⭐⭐ Excellent | ⭐⭐⭐⭐ Very Good | ⭐⭐ Limited |
| Barrier Protection | ⭐⭐ Moderate | ⭐⭐⭐⭐ Good | ⭐⭐⭐⭐⭐ Excellent |
| Chloride Resistance | ⭐⭐ Moderate | ⭐⭐⭐⭐ Good | ⭐⭐⭐⭐⭐ Excellent |
| Coating Density | ⭐⭐⭐ Moderate | ⭐⭐⭐⭐⭐ Very Dense | ⭐⭐⭐ Moderate |
| Abrasion Resistance | ⭐⭐ Low | ⭐⭐⭐⭐ Good | ⭐⭐⭐ Moderate |
| Cost | $ Baseline | $$ Moderate | $$$ Higher |
| Best For | General structural, indoor | Marine, bridge, infrastructure ★ | Chemical, high-temp |
Applications & Proven Case Studies
🌉 Bridge & Highway Steel
Rainbow Bridge (USA-Canada), Auckland Harbour Bridge (NZ), and numerous DOT projects specify 85/15 Zn-Al metallizing for 30+ year corrosion protection.
🏭 Storage Tanks & Pipelines
Above-ground storage tanks, chemical vessels, and water/wastewater infrastructure requiring long-term dual protection.
⚓ Marine & Offshore
Offshore platforms, lock gates, port equipment - 85/15 outperforms pure zinc by up to 3x in chloride exposure.
🏗️ Architectural & Utility
Light poles, transmission towers, stadium structures demanding low-maintenance corrosion systems.
📩 Need a Quote or Technical Datasheet?
We supply 85/15 Zn-Al wire (Zn85Al15) per ASTM B833 with full SGS traceability, competitive FOB/CIF pricing, and export-ready packaging.
📧 sale@zanewmetal.com | 🌐 www.za-refractory.com |
FOB Tianjin / Shanghai • CIF Rotterdam • CIF Busan • Free samples available
Frequently Asked Questions
What does "85/15" mean in Zn-Al wire?
85/15 refers to the alloy composition by weight: 85% zinc (±1%) and 15% aluminum (±1%). This specific ratio optimizes the balance between zinc's sacrificial cathodic protection and aluminum's passive barrier protection for thermal spray corrosion protection applications.
What purity is 85/15 Zn-Al thermal spray wire?
Our wire uses Special High Grade (SHG) zinc of 99.99% purity per ASTM B6 and primary aluminum ingot of 99.7% purity per EN 576. Total Zn+Al content exceeds 99.95% with very low impurity levels. No recycled scrap is used.
What standards does 85/15 Zn-Al wire meet?
Our wire complies with ASTM B833-20, ISO 14919, DIN 14919:2001, EN 1179 Z1, and EN 573-3. Application standards include SSPC CS 23.00 / NACE No. 12 / AWS C2.23M. Each batch ships with an SGS mill test certificate.
How does 85/15 Zn-Al compare to pure zinc wire?
85/15 offers significantly better corrosion resistance in chloride (marine) environments and produces a denser coating with higher abrasion resistance. Pure zinc wire has superior cathodic reach ("throwing power") but lower durability in aggressive conditions. For bridge and marine infrastructure, 85/15 is the preferred specification.
What diameters are available?
Standard diameters: 1.6 mm (1/16") and 3.2 mm (1/8"). Custom diameters are available on request to match specific arc spray or flame spray equipment.
About ZhenAn International Co., Limited
ZhenAn International Co., Limited (a subsidiary of Gnee Group) is a dedicated supplier of high-purity metal wires for thermal spray and metallizing applications. We serve bridge contractors, oil & gas EPC firms, marine engineering companies, and industrial coating applicators across North America, Europe, Southeast Asia, and the Middle East. Our 85/15 Zn-Al wire is produced under strict quality controls with full traceability from raw material to finished spool.
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