Zinc Spray Gun: Working, Types, Applications and Latest Price in India
Rust and corrosion damage steel structures, tanks, pipes and machine parts, and repairing them is expensive. A zinc spray gun applies a protective layer of zinc on the surface, which shields the steel from moisture and corrosion for years. This guide explains what a zinc 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 a zinc spray gun in India.
What Is a Zinc Spray Gun?
A zinc spray gun is a flame spray gun that melts zinc and sprays it onto a prepared surface to form a protective coating. In the flame spray process, molten metal such as zinc, copper or aluminium is sprayed onto a surface. The gun is named after the metal it sprays:
- Zinc spray gun: sprays zinc
- Copper spray metalizing gun: sprays copper
- Aluminium spray gun: sprays aluminium
The coating material can be fed as thermal spray wire or thermal spray powder. The wire or powder is melted in the gun and atomised with compressed air, and the molten droplets solidify on the surface of the base metal. A good zinc spray gun is light enough to be held and controlled in one hand, and it can run on compressed air or be motor-driven.
How Does a Zinc Spray Gun Work?
The process follows four steps:
- Surface preparation: The surface is cleaned and roughened with a sandblasting machine or grit blasting machine so that the zinc coating bonds firmly.
- Melting: In a flame spray gun, the zinc wire or powder is melted by a fuel gas flame. In a wire arc spray gun, two zinc wires are given opposite electric charges and fed close together, which creates an electric arc that melts them.
- Atomising: Compressed air breaks the molten zinc into fine droplets and carries them towards the surface.
- Coating build-up: The droplets hit the prepared surface, flatten and solidify into a dense zinc layer.
Because the base metal receives little heat, the component is not distorted, and the coating thickness is easy to control.
Main Types of Zinc Spray Guns
Zinc spray guns are mainly classified by how they melt the material:
- Flame spray gun (wire): Melts zinc wire in a fuel gas flame. It is simple to operate and widely used for corrosion protection.
- Flame spray gun (powder): Melts zinc or alloy powder in a flame, and is used where powder feeding suits the job.
- Wire arc spray gun: Uses an electric arc between two wires and gives high deposition rates, which makes it ideal for large structures.
- Compressed air or motor driven guns: The gun can be powered by compressed air or by an electric motor, depending on the working setup.
Zinc spray gun price in India: The price depends on the gun type, power source, material and the accessories supplied. Airo Shot Blast Equipments offers flame spray guns for zinc, copper and aluminium spraying. For the latest price, share your application details and we will send you a suitable quotation.
Typical specification:
| Parameter | Specification |
|---|---|
| Condition | New |
| Gun Material | Iron / Stainless Steel |
| Power | 1 kW |
| Weight | 3 kg |
| Voltage | 380V / 220V |
| Dimension (L×W×H) | 460 × 480 × 670 mm |
| Type | Coating Spray Gun |
| Supply Ability | 50 sets per week |
Performance highlights: The high-velocity zinc spray gun is efficient and low in power consumption. It combines air control and electric control, so operation is more convenient. Particle velocity can reach above 420 m/s, axial air speed can reach 600 m/s, and the coating deposition rate is above 75%.
Where Are Zinc Spray Guns Used?
Zinc spray coating is used wherever steel needs long-term protection against rust:
- Bridges, towers and steel structures
- Storage tanks, pipelines and pressure vessels
- Marine and offshore equipment
- Power plants and substations
- Automobile and mechanical parts
- Gates, railings and fabricated steel products
Zinc is also sprayed on parts where a sacrificial layer is needed, because it corrodes first and protects the steel underneath.
What Abrasive Should Be Used?
Zinc 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 zinc will not adhere properly. Use clean, dry, angular abrasive and spray soon after blasting, before the surface oxidises. A suitable shot blasting machine and the correct abrasive size give the best coating life.
Important Safety Considerations
Zinc spraying involves heat, compressed air, fuel gases and metal fumes, 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. Zinc fumes can cause illness if inhaled.
- 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
- Fuel gases are highly flammable. 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
- Check that the gun’s electrical supply (220V or 380V) is properly earthed before use.
- Only trained operators should run a zinc spray gun, following the manufacturer’s air pressure and gas settings.
- Never point the gun at a person, and shut off the air and gas fully when you stop spraying.
- Inspect nozzles and hoses regularly and replace worn parts promptly with genuine thermal spray gun spare parts.
Looking to Buy a Zinc Spray Gun?
Whether you need a zinc spray gun, a flame spray gun, thermal spray equipment or a blasting machine for surface preparation, Airo Shot Blast Equipments can guide you to the right setup for your application. Contact us today for the latest zinc spray gun price in India and a customised quotation.
Zinc Spray Gun of this type is adjusted to be supported and managed by one hand and, in order that it may not be too heavy, it should be made, as far as practicable, from Zinc. Zinc spray gun price latest price in india, however, is too soft to be advantageously used for both parties of the threaded connection among the top nozzle the repository and the cap to which the spray nozzle is connected. This spray gun sprays out from the gun to have a zinc coating on the material. This gun works compressed air or motor-driven.
Zinc Spray Gun latest price in India
Airo Shot Blast Equipments offers Flame Spray gun, Flame Spray Process is primarily the spray of molten metal like zinc, copper, aluminum on the surface for providing a coating. when gun sprayed zinc then called Zinc Spray Gun, Copper is Spraying then it is Copper spray metalizing gun & when gun spray Aluminum then it will be Aluminum spray gun. The molten metal can be wire form and powder form depend on the form. Coating wire or powder is melted in a gun and atomized with compressed air and deposit on the surface. The molten metal drops solidify on the surface of the substrate.
