Development of fine WC-NiCr powder coatings by optimising HVOF spray parameters
Surinder Singh, Alexander Osi, Vinit Vilas Joshi, Scott A. Wade, Christopher C. Berndt, Thomas Schläfer, Hugo Howse, Andrew Siao Ming Ang
Abstract
Thermal spray processing parameters need to be optimised to mitigate decarburisation and oxidation of carbide-based coatings that causes unacceptable brittleness. In the present work, a theoretical model was developed to optimise kerosene fuelled high-velocity oxy-fuel (HVOF) flame characteristics and spray parameters for producing high-quality WC-NiCr coatings using finer feedstock of particle size distribution of – 30 + 5 μm. The model suggested an oxygen-to-kerosene ratio of 3.3 and a shorter torch barrel to avoid decarburisation in coatings. In total four parameter sets suggested by the theoretical model were selected to spray the fine-cut powder using a 100 mm long torch barrel. The developed theoretical framework was successful to provide optimised set of HVOF spray parameters to deposit high-quality fine carbide coatings with less decarburisation. Also, the coatings deposited using the optimised set of parameters exhibited the best performance in terms of low porosity, inter-splat cracks, brittleness, as-spray surface roughness, and corrosion resistance. Hence, the optimised parameters can be used to produce a finer as-sprayed finish, thereby demonstrating the potential in reducing grinding efforts.