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Process Control and Characterization of NiCr Coatings by HVOF-DJ2700 System: A Process Map Approach

Abstract

The concept of ‘process maps’ has been utilized to study the fundamentals of process-structure-property relationships in high velocity oxygen fuel (HVOF) sprayed coatings. Ni-20%Cr was chosen as a representative material for metallic alloys. In this paper, integrated experiments including diagnostic studies, splat collection, coating deposition, and property characterization were carried out in an effort to investigate the effects of fuel gas chemistry (fuel/oxygen ratio), total gas flow, and energy input on particle states: particle temperature (T) and velocity (V), coating formation dynamics, and properties. Coatings were deposited on an in situ curvature sensor to study residual stress evolution. The results were reconciled within the framework of process maps linking torch parameters with particle states (1st order map) and relating particle state with deposit properties (2nd order map). A strong influence of particle velocity on induced compressive stresses through peening effect is discussed. The complete tracking of the coating buildup history including particle state, residual stress evolution and deposition temperature, in addition to single splat analysis, allows the interpretation of resultant coating microstructures and properties and enables coating design with desired properties.

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Acknowledgments

This research was supported by the GOALI-FRG program of the National Science Foundation under award number CMMI 0605704 and by the Consortium of Thermal Spray Technology at the Center for Thermal Spray Research in Stony Brook University. The authors would like to thank Prof. Margaret Hyland and Anh Tran for the FIB micrographs.

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Correspondence to Alfredo Valarezo.

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Valarezo, A., Choi, W.B., Chi, W. et al. Process Control and Characterization of NiCr Coatings by HVOF-DJ2700 System: A Process Map Approach. J Therm Spray Tech 19, 852–865 (2010). https://doi.org/10.1007/s11666-010-9492-1

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Keywords

  • HVOF
  • mechanical properties
  • NiCr
  • process control
  • process maps
  • residual stress
  • transport properties