Optimisation of HVOF Spray Process Parameters to Achieve Minimum Porosity and Maximum Hardness in WC-10Ni-5Cr Coatings
Source abstract
Abstract
High-velocity oxy-fuel (HVOF) spray coating plays a major role in many surface treatment methods, which tend to improve erosion and corrosion resistance properties. HVOF is well known for its dense and high-quality coating ability. This is due to the less in-flight exposure time, which tends to have less oxide content because of its high-velocity properties. Among the number of process parameters, porosity and hardness are predominant factors while considering wear rate and corrosion behaviour analysis. The current study aims to optimise HVOF process parameters to obtain low levels of porosity and high hardness values in the WC-10Ni-5Cr coating sprayed on 35 Mo Cr steel. The flow rates of oxygen, LPG, coating powder feed rate and spray distance are selected in this study as these have a superior influence on the final condition of the coating. Statistical tools such as the design of experiments (DoE), analysis of variants and response surface methodology (RSM) were used to achieve the desired results. As per the result analysis, the oxygen flow rate has a higher effect on the porosity value and microhardness value of the coating.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: High-Temperature Coating Behaviors · Advanced materials and composites · Erosion and Abrasive Machining
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Manufacturing Engineering, Annamalai University, Annamalai Nagar 608002, India
Department of Materials Science and Engineering, The State University of New York (SUNY), Stony Brook, New York, NY 11794, USA
Department of Mechanical Engineering, Government College of Engineering, Bargur, Krishnagiri 635104, India
Department of Mechanical Engineering, Institute of Road Transport Polytechnic College, Bargur, Krishnagiri 635104, India
Department of Mechanical Engineering, Alagappa Chettiar Government College of Engineering and Technology, Karaikudi 63003, India
Department of Mechanical Engineering, Government Polytechnic College, Valangaiman, Thiruvarur 612804, India
Department of Mechanical Engineering, Mohandas College of Engineering and Technology, Trivandrum 69554, India
References (27)
Show source-provided references
1. Vaßen, R., Bakan, E., Gatzen, C., Kim, S., Mack, D.E., and Guillon, O. (2019). Environmental Barrier Coatings Made by Different Thermal Spray Technologies. Coatings, 9.10.3390/coatings9120784 ↗
2. Joshi, S., and Nylen, P. (2019). Advanced Coatings by Thermal Spray Processes: A review. Technologies, 7.10.3390/technologies7040079 ↗
3. Improvement of copper alloy properties in electro-explosive spraying of ZnO-Ag coatings resistant to electrical erosion10.1016/j.jmrt.2019.09.019 ↗
4. Mohankumar, A., Duraisamy, T., Chidambaramseshadri, R., Pattabi, T., Ranganathan, S., Kaliyamoorthy, M., Balachandran, G., Sampathkumar, D., and Rajendran, P.R. (2022). Enhancing the Corrosion Resistance of Low Pressure Cold Sprayed Metal Matrix Composite Coatings on AZ31B Mg Alloy through Friction Stir Processing. Coatings, 12.10.3390/coatings12020135 ↗
5. Kannan, M., Duraisamy, T., Pattabi, T., and Mohankumar, A. (2021). Investigate the corrosion properties of stellite coated on AZ91D alloy by plasma spray technique. Therm. Sci., 209.10.2298/TSCI200722209K ↗
6. Influences of Mechanical, Corrosion, erosion and tribological performance of cold sprayed Coatings A review10.1016/j.matpr.2021.01.664 ↗
7. Study on thermal, mechanical, microstructural properties and failure analyses of lanthanum zirconate based thermal barrier coatings: A review10.1016/j.matpr.2021.02.672 ↗
8. Straffelini, G., and Federici, M. (2020). HVOF Cermet Coatings to Improve Sliding Wear Resistance in Engineering Systems: A review. Coatings, 10.10.3390/coatings10090886 ↗
9. Brezinová, J., Guzanová, A., Tkáčová, J., Brezina, J., Ľachová, K., Draganovská, D., Pastorek, F., Maruschak, P., and Prentkovskis, O. (2020). High Velocity Oxygen Liquid-Fuel (HVOLF) Spraying of WC-Based Coatings for Transport Industrial Applications. Metals, 10.10.3390/met10121675 ↗
10. Tilger, M., Biermann, D., Abdulgader, M., and Tillmann, W. (2019). The Effect of Machined Surface Conditioning on the Coating Interface of High Velocity Oxygen Fuel (HVOF) Sprayed Coating. J. Manuf. Mater. Process., 3.10.3390/jmmp3030079 ↗
11. Wu, M., Pan, L., Duan, H., Wan, C., Yang, T., Gao, M., and Yu, S. (2021). Study on Wear Resistance and Corrosion Resistance of HVOF Surface Coating Refabricate for Hydraulic Support Column. Coatings, 11.10.3390/coatings11121457 ↗
12. Corrosion and mechanical performance of HVOF WC-based coatings with alloyed nickel binder for use in marine hydraulic applications10.1016/j.surfcoat.2021.127239 ↗
13. Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings10.1016/j.dt.2017.03.001 ↗
14. Developing empirical relationships to estimate porosity and microhardness of plasma-sprayed YSZ coatings10.1016/j.ceramint.2013.09.125 ↗
15. Slurry Erosion Behavior of HVOF-Sprayed Amorphous Coating on Stainless Steel10.1007/s13632-019-00552-1 ↗
16. Sensitivity analysis and optimisation of HVOF process inputs to reduce porosity and maximise hardness of WC-10Co-4Cr coatings10.1007/s12046-021-01667-4 ↗
17. Influence of rotational speed, angle of impingement, concentration of slurry and exposure time on erosion performance of HVOF sprayed cermet coatings on 35CrMo steel10.1016/j.matpr.2021.01.307 ↗
18. Experimental Investigation and Optimization of HVOF Spray Parameters on Wear Resistance Behaviour of Ti-6Al-4V Alloy
19. Wet abrasive wear behavior of WC-based cermet coatings prepared by HVOF spraying10.1016/j.ceramint.2020.09.009 ↗
20. Optimization of HVOF spray parameters to attain minimum porosity and maximum hardness in WC-10 Ni-4 Cr coatings10.1016/j.surfcoat.2014.03.022 ↗
21. Optimization Parameters of WC-12Co HVOF Sprayed Coatings on SUS 400 Stainless Steel10.1016/j.promfg.2019.02.071 ↗
22. Process characteristics, particle behavior and coating properties during HVOF spraying of conventional, fine and nanostructured WC-12Co powders10.1016/j.surfcoat.2020.126716 ↗
23. Novel liquid fuel HVOF torches fueled with ethanol: Relationships between in-flight particle characteristics and properties of WC-10Co-4Cr coatings10.1016/j.surfcoat.2020.126805 ↗
24. Properties of coatings created by HVOF technology using micro-and nano-sized powder10.2478/kom-2019-0011 ↗
25. Relationships between in-flight particle characteristics and properties of HVOF sprayed WC-CoCr coatings10.1016/j.jmatprotec.2013.09.029 ↗
26. Improving the wear resistance of HVOF sprayed WC-Co coatings by adding submicron-sized WC particles at the splats’ interfaces10.1016/j.surfcoat.2015.11.017 ↗
27. Optimization and prediction of AZ91D stellite-6 coated magnesium alloy using Box Behnken design and hybrid deep belief network10.1016/j.jmrt.2021.09.069 ↗