Aluminium Spray Gun: Working, Types, Applications and Price in India
Rust and oxidation shorten the life of steel pipelines, tanks, valves and offshore structures. An aluminium spray gun applies a protective aluminium layer on the surface of the component, so it can resist corrosion for many years with very little maintenance. This guide explains what an aluminium spray gun is, how it works, the main types available, where it is used and which abrasive to choose for surface preparation. It also covers safety practices and what to know before you buy an aluminium spray gun in India.
What Is an Aluminium Spray Gun?
An aluminium spray gun is a thermal spray gun used to coat the surface of a base metal (substrate) with aluminium wire, so that the component is protected from rust and oxidation. The wire is melted inside the gun and sprayed across the surface of the component, where the molten droplets solidify into a protective layer.
Aluminium coating offers several advantages:
- Reduces the risk of rust and corrosion
- Protects against mechanical damage
- Needs minimum maintenance
- Extends the life of the metal component
- Heat distortion is not normally a problem
How Does an Aluminium Spray Gun Work?
The process follows these steps:
- Surface preparation: The substrate is cleaned and roughened with a sandblasting machine so that the aluminium coating bonds firmly. Coating is always done after this step.
- Wire feeding: Rollers inside the gun push and pull the aluminium wire forward and backward to feed it at a steady rate.
- Melting: In a flame spray gun, oxygen with acetylene, or sometimes LPG, melts the wire. In an arc spray gun, an electric arc between the cathode and anode melts or semi-melts the material.
- Atomising and coating: Compressed air breaks the molten or semi-molten metal into fine droplets and sprays them onto the prepared surface.
Gas flow control: A gas flow meter is used to check and set the flow of oxygen and acetylene (or LPG) according to the requirement. Too much gas flow (oxygen, LPG or acetylene, and compressed air) can damage the spray gun and the coating material. If the gas flow is not balanced, an even coating is also hard to achieve on the surface.
Main Types of Aluminium Spray Guns
Aluminium spray guns are mainly classified by how they melt the wire:
- Flame spray gun: Uses oxygen with acetylene or LPG to melt the wire, and compressed air to atomise it. It is simple to operate and common for general corrosion protection.
- Arc spray gun: Uses an electric arc between two wires to melt the material. It gives a high spray rate and suits large surfaces.
- Wire fed guns with roller drive: Rollers push and pull the wire for smooth, consistent feeding in both types.
Aluminium spray gun p rice in India: The price depends on the gun type, melting method, material and the accessories supplied, such as the gas flow meter, wire feeder and thermal spray equipment package. For the latest price, share your application details and we will send you a suitable quotation.
Where Are Aluminium Spray Guns Used?
Aluminium coating is used wherever steel needs strong protection against rust and oxidation:
- Subsea pipelines
- Offshore platforms
- Header boxes
- Valves
- Heat exchangers
- Tanks and vessels
Aluminium spray guns also suit bridges, marine equipment, power plants and fabricated steel structures that face weather, moisture or heat.
5. What Abrasive Should Be Used?
Aluminium coating bonds well only to a clean, rough surface, so blasting before spraying is essential:
- Aluminium oxide: The most widely recommended abrasive for thermal spray preparation. It is hard and angular and gives a consistent surface profile.
- Chilled iron grit or steel grit: Suitable for heavy steel components that need a deeper profile.
- Silicon carbide: Used for very hard base materials.
Avoid round abrasives such as steel shot or glass beads, because they peen the surface instead of roughening it, and the coating will not adhere properly. Use clean, dry, angular abrasive and spray soon after blasting, before the surface oxidises. A suitable grit blasting machine or shot blasting machine and the correct abrasive size give the best coating life.
Important Safety Considerations
Aluminium spraying involves heat, compressed gases, metal fumes and noise, so safe practices protect both operators and equipment.
Personal protective equipment (PPE)
- Wear a respirator or an air-fed blasting helmet approved for metal fumes and dust.
- Use hearing protection, as spray guns can be loud.
- Wear heat-resistant sandblasting hand gloves, flame-retardant blasting suits, safety boots and tinted eye protection.
Gas and fire safety
- Oxygen, acetylene and LPG are hazardous gases. Store gas cylinders upright, secured and away from heat, using a gas cylinder trolley or cylinder stand.
- Check gas hoses, gas regulators and fittings for leaks before every use, and use flashback arrestors.
- Keep fire extinguishers nearby and keep oxygen away from oil and grease.
Spray area and ventilation
- Spray in a well-ventilated area or a spray booth with a dust collector and filtration system to remove fumes.
- Keep unauthorised people out of the spray area while the gun is running.
Electrical and operator practices
- For arc spray guns, make sure the electrical supply is properly earthed before use.
- Only trained operators should run an aluminium spray gun, following the manufacturer’s gas and air settings.
- Never point the gun at a person, and shut off the gases and air fully when you stop spraying.
- Inspect nozzles, rollers and hoses regularly and replace worn parts promptly with genuine thermal spray gun spare parts.
Looking to Buy an Aluminium Spray Gun?
Whether you need an aluminium spray gun, thermal spray equipment or a blasting machine for surface preparation, our team can guide you to the right setup for your application. Contact us today for the latest aluminium spray gun price in India and a customised quotation.
