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Influence of Particle Size Distribution on the Morphology and Cavitation Resistance of High-Velocity Oxygen Fuel Coatings

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Abstract

The cavitation wear process is one of the major wear mechanisms in turbines and rotors of hydroelectric power plants in Brazil. An effective way to increase the cavitation resistance is the use of coatings, applied by thermal spraying. The high-velocity oxy-fuel process (HVOF) is one of the most used thermal spraying processes, and it is widely adopted for applying coatings for protection against wear and in maintenance components. A FeCrMnSiB experimental alloy was deposited onto SAE 1020 substrate by HVOF process, in order to evaluate the influence of the powder particle size range on the morphology and cavitation resistance of the coatings. The morphology of the coatings showed an increase in oxide content with powder size reduction. The increase in the powder particle size reduced the wettability of the particles, observed by the increase in the quantity of non-melted particles. Higher particle size distribution led to an increase in erosion rate, due to higher presence of non-melted particles in the coatings and consequently reduction of splats adhesion. The cavitation damage was perceived mainly by the mechanism of lamellae detachment; however, part of the damage was also absorbed by strain hardening due to the γ-ε martensitic transformation.

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Acknowledgments

The authors thank the Federal University of Technology Paraná, Ponta Grossa, Brazil (UTFPR-PG), the Thermal Spray and Special Welding Laboratory from Federal University of Paraná, Curitiba, Brazil (LABATS - UFPR), and the Institutos LACTEC, Curitiba, Brazil, for the availability of research structure. The Clausthal University of Technology, Germany, for the atomization of powder for this research. The Revesteel Metallization Company, Brazil, for the HVOF deposition. The Copel Geração e Transmissão S/A, for funding the research Project ANEEL PD-6491-0023/2010. The Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) for the provision of the scholarship, which assisted in the development of this work.

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Authors and Affiliations

  1. Post-graduate Program in Mechanical Engineering, Federal University of Technology - Parana, Ponta Grossa, PR, Brazil

    L. L. Silveira & A. G. M. Pukasiewicz

  2. Post-graduate Program in Mechanical Engineering, Federal University of Paraná, Curitiba, PR, Brazil

    G. B. Sucharski & R. S. C. Paredes

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  1. L. L. Silveira
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  3. A. G. M. Pukasiewicz
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Silveira, L.L., Sucharski, G.B., Pukasiewicz, A.G.M. et al. Influence of Particle Size Distribution on the Morphology and Cavitation Resistance of High-Velocity Oxygen Fuel Coatings. J Therm Spray Tech 27, 695–709 (2018). https://doi.org/10.1007/s11666-018-0708-0

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