Mechanical and thermal properties of HVOF sprayed Ni based alloys with carbide

The objective of the present study is to develop multi-functioned coating to the components, which are made of copper with electroplated Ni and are widely used for steel making industry. In this paper, we report the mechanical and thermal properties of Ni based superalloys with carbide sprayed by high velocity oxygen fuel (HVOF), and the detailed effects of sprayed material, spraying conditions, and initial powder structure on these properties. It was found that, among commercial Ni self-fluxing alloys (without fusing treatment), coating with a carbon content of 0.58 mass% had the most preferable properties, with a good balance of the hardness, strength, and thermal shock resistance. The thermal shock resistance depended not only on the strength of the coating but also on the volume contraction when tested at high temperatures. For the several developed Ni based superalloys with carbide, Ni20Cr8Mo5Fe–WC and Ni16Cr15Mo3–WC demonstrated the prominent adhesion strength and thermal shock resistance with high Galvanic corrosion resistance through optimized spraying condition. Also, 20 mass% NiCr–Cr3C2 coating sprayed by using employed relatively small primary particle succeeded in achieving the multi-superior properties; high adhesion strength, high corrosion resistance and thermal shock resistance.