Amorphous phase formation of Zr-based alloy coating by HVOF spraying process

This investigation was conducted to clarify the effects of process parameters on the formation of the new amorphous coating using a Zr-based alloy, which is known as bulk metallic glass forming alloy, by a HVOF (High Velocity Oxygen Fuel) spraying process. Powders used for spraying was prepared by vacuum gas atomization and then crushed by a centrifugal mill. HVOF spraying experiments were carried out using a Tafa JP-5000 spraying gun. DTA (Differential Thermal Analysis) measurements have shown that the amorphous content of the coatings was measured up to about 62% depending on the spraying process parameters. The amorphous fraction of the coatings is decreased with increasing the spray distance and the fuel flow rate. Microstructural observations and X-ray diffraction analysis of the spray coated layers reveal that the amorphization behavior during the spraying is attributed to the degree of the solidification of droplets and the oxide (ZrO2) formation in spray coated layers. Therefore, flame temperature and spray distance that can control the carrier gas temperature and undercooling effects of the droplets are the most crucial factors for the evolution of the amorphous phase using this bulk metallic glass forming alloy.