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KappAloy™ & EcoBabbitt Spray Wires in Capacitor Manufacturing


KappAloy™ Tin-Zinc & EcoBabbitt coatings are applied to capacitors as a protective coating;

  1. To connect the layers of the capacitor electrodes;
  2. To create a conductive surface for the connection of terminals;
  3. To shield sensitive electronics against Electromagnetic Interference (EMI) & Radio Frequency Interference (RFI);
  4. To shield against corrosion;
  5. To prevent current and charge leakage out of and within the capacitor; and,
  6. To prevent the development of electron flows within the coating material itself. These currents diminish coating effectiveness, capacitor performance and capacitor life.


The Challenge of Manufacturing Consistent Tin-Zinc & Tin-Zinc-Copper Spray Wire, and Why It Matters to Your Bottom Line

The typical manufacturing method for Tin-Zinc and Tin-Zinc-Copper spray wire alloys is to form billets of the alloy, and then extrude wire from these billets using an extrusion press. The larger the diameter of the billet, the more wires can be extruded at the same time, thus increasing press output, and decreasing costs.

Unfortunately, Tin-Zinc and Tin-Zinc-Copper alloys segregate during billet and wire cooling; the greater the diameter of the billet, the greater the segregation of the alloy during cooling. Segregation can lead to wire that is substantially off-alloy and inconsistent, resulting in wire breakage, gun clogging, high porosity, and poor deposition during thermal spraying. In addition, this can result in an uneven bimetallic coating rather than a consistent alloy coating. An inconsistent coating results in diminished performance in all six of the desired characteristics above.

Kapp Precision Microcasting™ Solves Your Spray Wire Problems


Kapp Alloy developed the proprietary Precision Microcasting process specifically to address the adverse effects of segregation during billet and wire formation. Our Precision Microcasting process forms the wire directly from the molten alloy. The wire cools extremely quickly, maintaining a precise alloy from edge-to-edge and end-to-end through thousands of pounds of wire.


Precision Microcastingprevents:

  • Excessive spray head wear and clogging,
  • Inconsistent spray gun performance due to inconsistent alloys,
  • Excessive wear of spray gun feed components due to scale and segregation,
  • Excessive wire breakage and feed jams due to inconsistent alloys,
  • Improper coating deposition, porosity, hot spots, and inclusions,
  • Current and charge buildup due to inconsistent alloys, and
  • Corrosion and component failure due to inconsistent porous spray coatings.

Kapp Alloy Precision Microcast spray wire avoids the wire segregation, brittleness, and wire breakage of extruded wires that can bring your spray wire operation to a grinding halt. Whether your process calls for 100 lbs./month or 1000 lbs./day, our Precision Microcasting process guarantees superior wire edge-to-edge and end-to-end.


Learn more about using KappAloy & Kapp EcoBabbitt spray wires.


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