Abstract
The coating quality by the high-velocity oxyfuel (HVOF) thermal spray process is greatly dependent on the operating parameters chosen during the operation. Depending on the application, the operating conditions are manipulated to enhance the desired coating property. Enhancement of multiple properties necessitates optimization of the operating conditions. This entails a comprehensive analysis of several coatings deposited at different operating conditions. The design of experiments is an effective method that helps in identifying optimum operating conditions with a reduced number of experiments. In the present study, a 24 factorial design approach is used to establish the relationships between four operating parameters (coating thickness, fuel/oxygen ratio, spraying distance, and powder injection rate) and three coating properties (roughness, microhardness, and contact angle). The results obtained are utilized in identifying the optimum parameters that produce the best coating quality. Furthermore, the study also compares the coating quality obtained by the HVOF thermal spray process with that by chrome plating. The results show that the HVOF thermal spray process produces superior coating quality and it can be a promising environmentally friendly candidate for replacing chrome plating.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig1_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs00170-019-03696-0/MediaObjects/170_2019_3696_Fig10_HTML.png)
Similar content being viewed by others
References
Guilemany JM, Espallargas N, Suegama PH, Benedetti AV (2006) Comparative study of Cr3C2–NiCr coatings obtained by HVOF and hard chromium coatings. Corros Sci 48(10):2998–3013
Picas JA, Forn A, Matthäus G (2006) HVOF coatings as an alternative to hard chrome for pistons and valves. Wear 261(5–6):477–484
Wan S, Li D, Zhang G, Tieu AK, Zhang B (2017) Comparison of the scuffing behaviour and wear resistance of candidate engineered coatings for automotive piston rings. Tribol Int 106:10–22
Pierce D, Haynes A, Hughes J, Graves R, Maziasz P, Muralidharan G, Shyam A, Wang B, England R, Daniel C (2019) High temperature materials for heavy duty diesel engines: historical and future trends. Prog Mater Sci 103:109–179
Savarimuthu AC, Taber HF, Megat I, Shadley JR, Rybicki EF, Cornell WC, Emery WA, Somerville DA, Nuse JD (2001) Sliding wear behavior of tungsten carbide thermal spray coatings for replacement of chromium electroplate in aircraft applications. J Therm Spray Technol 10(3):502–510
Legg KO, Graham M, Chang P, Rastagar F, Gonzales A, Sartwell B (1996) The replacement of electroplating. Surf Coat Technol 81(1):99–105
Fedrizzi L, Rossi S, Cristel R, Bonora PL (2004) Corrosion and wear behaviour of HVOF cermet coatings used to replace hard chromium. Electrochim Acta 49(17–18):2803–2814
Bolelli G, Cannillo V, Lusvarghi L, Riccò S (2006) Mechanical and tribological properties of electrolytic hard chrome and HVOF-sprayed coatings. Surf Coat Technol 200(9):2995–3009
Baral A, Engelken RD (2002) Chromium-based regulations and greening in metal finishing industries in the USA. Environ Sci Policy 5(2):121–133
Sartwell B, Legg K, Schell J, Sauer J, Natishan P (2004) Validation of HVOF WC/Co thermal spray coatings as a replacement for hard chrome plating on aircraft landing gear. Naval Research Lab, Washington DC
Houdková Š, Zahálka F, Kašparová M, Berger L-M (2011) Comparative study of thermally sprayed coatings under different types of wear conditions for hard chromium replacement. Tribol Lett 43(2):139–154
Bolelli G, Giovanardi R, Lusvarghi L, Manfredini T (2006) Corrosion resistance of HVOF-sprayed coatings for hard chrome replacement. Corros Sci 48(11):3375–3397
Gong T, Yao P, Zuo X, Zhang Z, Xiao Y, Zhao L, Zhou H, Deng M, Wang Q, Zhong A (2016) Influence of WC carbide particle size on the microstructure and abrasive wear behavior of WC–10Co–4Cr coatings for aircraft landing gear. Wear 362–363:135–145
Li M, Shi D, Christofides PD (2004) Diamond jet hybrid HVOF thermal spray: gas-phase and particle behavior modeling and feedback control design. Ind Eng Chem Res 43(14): 3632–3652
Roy R (2001) Design of experiments using the Taguchi approach: 16 steps to product and process improvement. John Wiley & Sons, New York
Montgomery DC (2017) Design and analysis of experiments. John wiley & sons, New York
Ji G-C, Li C-J, Wang Y-Y, Li W-Y (2007) Erosion performance of HVOF-sprayed Cr3C2-NiCr coatings. J Therm Spray Technol 16(4):557–565
Al-Bashir A, Jawwad AKA, Shgair KA (2009) Evaluating the effects of high velocity oxy-fuel (HVOF) process parameters on wear resistance of steel-shaft materials. Jordan J Mech Ind Eng 3(2):157–160
Nourouzi S, Azizpour MJ, Salimijazi HR (2014) Parametric study of residual stresses in HVOF thermally sprayed WC–12Co coatings. Mater Manuf Process 29(9):1117–1125
Katranidis V, Gu S, Allcock B, Kamnis S (2017) Experimental study of high velocity oxy-fuel sprayed WC-17Co coatings applied on complex geometries. Part A: influence of kinematic spray parameters on thickness, porosity, residual stresses and microhardness. Surf Coat Technol 311:206–215
Vackel A, Sampath S (2017) Fatigue behavior of thermal sprayed WC-CoCr- steel systems: role of process and deposition parameters. Surf Coat Technol 315:408–416
Varis T, Suhonen T, Calonius O, Čuban J, Pietola M (2016) Optimization of HVOF Cr3C2NiCr coating for increased fatigue performance. Surf Coat Technol 305:123–131
Sharma S (2012) Erosive wear study of rare earth-modified HVOF-sprayed coatings using design of experiment. J Therm Spray Technol 21(1):49–62
Hasan S (2009) Design of experiment analysis of high velocity oxy-fuel coating of hydroxyapatite. Dublin City University, Ireland
Al-Samarai RA, Haftirman AKR, Al-Douri Y (2012) Evaluate the effects of various surface roughness on the tribological characteristics under dry and lubricated conditions for Al-Si alloy. J Surf Eng Mater Adv Technol 2:167–173
Kietzig A-M, Hatzikiriakos SG, Englezos P (2009) Ice friction: the effects of surface roughness, structure, and hydrophobicity. J Appl Phys 106(2):024303
Levingstone TJ (2008) Optimisation of plasma sprayed hydroxyapatite coatings. Dublin City University, Ireland
Wang L, Wang Y, Sun XG, He JQ, Pan ZY, Wang CH (2012) Microstructure and indentation mechanical properties of plasma sprayed nano-bimodal and conventional ZrO2–8wt%Y2O3 thermal barrier coatings. Vacuum 86(8):1174–1185
Bico J, Thiele U, Quéré D (2002) Wetting of textured surfaces. Colloids Surfaces A Physicochem Eng Asp 206(1–3):41–46
Funding
This research was supported by the Government of Abu Dhabi to help fulfill the vision of the late President Sheikh Zayed Bin Sultan Al Nahyan for the sustainable development and empowerment of the UAE and humankind.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher’s note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Khan, M.N., Shah, S. & Shamim, T. Investigation of operating parameters on high-velocity oxyfuel thermal spray coating quality for aerospace applications. Int J Adv Manuf Technol 103, 2677–2690 (2019). https://doi.org/10.1007/s00170-019-03696-0
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-019-03696-0