Skip to main content
SpringerLink
Log in

Study on Structural Behavior of HVOF-Sprayed NiCr/Mo Coating

  • ORIGINAL CONTRIBUTION
  • Published:
Journal of The Institution of Engineers (India): Series D Aims and scope Submit manuscript

Abstract

This study investigates the structural behavior of HVOF-sprayed NiCr/Mo coating. The main objective of the coating is to improve the surface properties such as micro-cutting, cavity, and cracks, to avoid the corrosion, and to determine self-life and wear resistance at room temperature and high temperature also. The coating structures are very sensitive to processing and working conditions, to overcome all these aspects, the surface metal has to undergo microstructure analysis, porosity, microstructure hardness, and X-ray diffraction (XRD), and to improve mechanical properties of metal. HVOF spraying technique was used to deposit the coating on mild steel plate than the coated sample characterized using scanning electron microscope (SEM), X-ray diffraction (XRD), microhardness, microindentation, and wear test. Moreover, we introduce the NiCr/Mo at different percentage levels (5%, 10%, and 15%) to evaluate the mechanical properties, to improve the performance and life span of the fracturing operations in aggressive conditions, which is essential in components replacement and economic savings in various industries such as aerospace, automotive, marine, etc.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Data Availability

Not applicable.

References

  1. V. Matikainen, G. Bolelli, H. Koivuluoto, P. Sassatelli, L. Lusvarghi, P. Vuoristo, Sliding wear behaviour of HVOF and HVAF sprayed Cr3C2 based coating. Wear 388, 57–71 (2017)

    Article  Google Scholar 

  2. T.K. Mishra, A. Kumar, S.K. Sinha, S. Sharma, Investigation of sliding wear behavior of HVOF carbide coating. Mater. Today Proc. 5(9), 3–8 (2018)

    Google Scholar 

  3. R. Subbaih, A. Arun, A.A. Lakshmi, A.N.S. Harika, N. Ram, N. Sateesh, Experimental study of wear behavior on Al-2014 alloy coating with thermal spray HVOF and plasma spray process. Mater. Today Proc. 18, 5151–5157 (2019)

    Article  Google Scholar 

  4. H. Wang, Q. Qiu, M. Gee, C. Hou, X. Liu, X. Song, Wear resistance of HVOF sprayed WC-CO Coating by Complete densification of starting powder. Mater. Des. 191, 10586 (2020)

    Article  Google Scholar 

  5. D.G. Bhosle, W.S. Rathod, Investigation of wear behaviour of SS316L atmosperic plasma and HVOF sprayed WC- Cr3C2-N coating for fracture tools. Surf. Coat. Technol. 390, 125679 (2020)

    Article  Google Scholar 

  6. E.H. Williamson, M. Gee, D. Robertson, J.F. Watts, M.J. Whiting, J.A. Yeomans, A comparitive study of the wear performances of hard coatings for nuclear applications. Wear 488–489, 204124 (2022)

    Article  Google Scholar 

  7. Wear Performance analysis and characterization HVOF deposited Ni-20 Cr2O3, Ni-30 Al2O3 and Al2O3–13TiO2 coatings (2021)

  8. C.Y. Lee, T.-J. Lin, H.H. Sheu, H. Binley, A study on corrosion wear behavior of Fe – based amorphous alloy coating prepared by HVOF Method. J. Mater. Rese. Technol. 15, 4880–4895 (2021)

    Article  Google Scholar 

  9. J. Pulford, F. Venturi, S. Kamnis, T. Hussain, Sliding wear behavior of WC-CO reinforced NiCrFeSiB HVOF thermal spray coating against WC-Co and Al2O3 counter bodies. J. Surf. Coat. 386, 125468 (2020)

    Article  Google Scholar 

  10. R. Khuengpukheiw, A. Wisitsoraat, C. Saikaew, Wear behaviors of HVOF sprayed NiSiCrFeB, WC-Co/NiSiCrFeB and WC-Co coatings evaluated using a pin-on-disc tester with C45 steel pins. Wear 484, 203699 (2020)

    Google Scholar 

  11. N.G. Siddeshkumar, R. Suresh, C. Durga Prasad, L. Shivaram, N.H. Siddalingaswamy, Evolution of the surface quality and tool wear in the high speed turning of Al2219/n-B4C/MoS2 metal matrix composites. Int. J. Cast Met. Res. (2023). https://doi.org/10.1080/13640461.2023.2285177

    Article  Google Scholar 

  12. N. Praveen, U.S. Mallik, A.G. Shivasiddaramaiah, N. Nagabhushana, C. Durga Prasad, S. Kollur, Effect of CNC end milling parameters on Cu-Al-Mn ternary shape memory alloys using Taguchi method. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-023-00579-3

    Article  Google Scholar 

  13. C. Durga Prasad, S. Kollur, C.R. Aprameya, T.V. Chandramouli, T. Jagadeesha, B.N. Prashanth, Investigations on tribological and microstructure characteristics of WC-12Co/FeNiCrMo composite coating by HVOF process. JOM J. Miner. Met. Mater. Soc. (TMS) (2023). https://doi.org/10.1007/s11837-023-06242-2

    Article  Google Scholar 

  14. V. Srinivasa Chari, S. Jhavar, T.N. Sreenivasa, H. Hanumanthappa, C. Durga Prasad, B.K. Shanmugam, Impact of post-processing techniques on the wear resistance of plasma beam treatment on SS316L components. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-023-00584-6

    Article  Google Scholar 

  15. S. Gotagunaki, V.S. Mudakappanavar, R. Suresh, C. Durga Prasad, Studies on the mechanical properties and wear behavior of an AZ91D magnesium metal matrix composite utilizing the stir casting method. Metallogr. Microstruct. Anal. (2023). https://doi.org/10.1007/s13632-023-01017-2

    Article  Google Scholar 

  16. K.S. Lokesh, K. Shashank Kumar, N. Keerthan, R. Revanth, S. Sandeep, S.B. Lakkundi, V. Bharath, H. Hanumanthappa, C. Durga Prasad, B.K. Shanmugam, Experimental analysis of the rice husk and eggshell powder-based natural fibre composite. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-023-00557-9

    Article  Google Scholar 

  17. G. Srinivasa Rao, U. Mukkamala, H. Hanumanthappa, C. Durga Prasad, H. Vasudev, B. Shanmugam, K.C. Kishore Kumar, Evaluating and optimizing surface roughness using genetic algorithm and artificial neural networks during turning of AISI 52100 steel. Int. J. Interact. Des. Manuf. (IJIDeM) (2023). https://doi.org/10.1007/s12008-023-01549-5

    Article  Google Scholar 

  18. C. Manjunatha, T.N. Sreenivasa, P. Sanjay, C. Durga Prasad, Optimization of friction stir welding parameters to enhance weld nugget hardness in AA6061-B4C composite material. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-023-00562-y

    Article  Google Scholar 

  19. C. Durga Prasad, S. Kollur, M. Nusrathulla, G. SatheeshBabu, M.B. Hanamantraygouda, B.N. Prashanth, N. Nagabhushana, Characterisation and wear behaviour of SiC reinforced FeNiCrMo composite coating by HVOF process. Trans. IMF (2023). https://doi.org/10.1080/00202967.2023.2246259

    Article  Google Scholar 

  20. M. Arunadevi, M. Rani, R. Sibinraj, M.K. Chandru, C. Durga Prasad, Comparison of k-nearest neighbor & artificial neural network prediction in the mechanical properties of aluminum alloys. Mater. Today Proc. (2023). https://doi.org/10.1016/j.matpr.2023.09.111

    Article  Google Scholar 

  21. H. Sharanabasava, M. Raviprakash, C. Durga Prasad, M.R. Ramesh, M.V. Phanibhushana, H. Vasudev, S. Kumar, Microstructure, mechanical and wear properties of SiC and Mo reinforced NiCr microwave cladding. Adv. Mater. Process. Technol. (2023). https://doi.org/10.1080/2374068X.2023.2257937

    Article  Google Scholar 

  22. G.S. Kulkarni, N.G. Siddeshkumar, C. Durga Prasad, L. Shankar, R. Suresh, Drilling of GFRP with liquid silicon rubber reinforced with fine aluminium powder on hole surface quality and tool wear using DOE. J. Bio Tribo Corros. 9, 53 (2023). https://doi.org/10.1007/s40735-023-00771-8

    Article  Google Scholar 

  23. S.D. Kulkarni, M. Manjunatha, U. Chandrasekhar, K.V. Manjunath, C. Durga Prasad, H. Vasudev, Design and optimization of polyvinyl-nitride rubber for tensile strength analysis. Int. J. Interact. Des. Manuf. (IJIDeM) (2023). https://doi.org/10.1007/s12008-023-01405-6

    Article  Google Scholar 

  24. N. Praveen, U.S. Mallik, A.G. Shivasiddaramaih, R. Suresh, C. Durga Prasad, L. Shivaramu, Synthesis and wire EDM characteristics of Cu–Al–Mn ternary shape memory alloys using Taguchi method. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-023-00501-x

    Article  Google Scholar 

  25. G. MadhuSudana Reddy, C. Durga Prasad, S. Kollur, A. Lakshmikanthan, R. Suresh, C.R. Aprameya, Investigation of high temperature erosion behaviour of NiCrAlY/TiO2 plasma coatings on titanium substrate. JOM J. Miner. Met. Mater. Soc. (TMS) (2023). https://doi.org/10.1007/s11837-023-05894-4

    Article  Google Scholar 

  26. N. Praveen, U.S. Mallik, A.G. Shivasiddaramaih, R. Suresh, L. Shivaramu, C. Durga Prasad, M. Gupta, Design and Analysis of shape memory alloys using optimization techniques. Adv. Mater. Process. Technol. (2023). https://doi.org/10.1080/2374068X.2023.2208021

    Article  Google Scholar 

  27. G. Madhusudana Reddy, C. Durga Prasad, P. Patil, N. Kakur, M.R. Ramesh, High temperature erosion performance of NiCrAlY/Cr2O3/YSZ plasma spray coatings. Trans. IMF (2023). https://doi.org/10.1080/00202967.2023.2208899

    Article  Google Scholar 

  28. H. Sharanabasva, C. Durga Prasad, M.R. Ramesh, Characterization and wear behavior of NiCrMoSi microwave cladding. J. Mater. Eng. Perform. (2023). https://doi.org/10.1007/s11665-023-07998-z

    Article  Google Scholar 

  29. G. Madhusudana Reddy, C. Durga Prasad, P. Patil, N. Kakur, M.R. Ramesh, Investigation of plasma sprayed NiCrAlY/Cr2O3/YSZ coatings on erosion performance of MDN 420 steel substrate at elevated temperatures. Int. J. Surf. Sci. Eng. 17(3), 180–194 (2023). https://doi.org/10.1504/IJSURFSE.2023.10054266

    Article  Google Scholar 

  30. H. Sharanabasva, C. Durga Prasad, M.R. Ramesh, Effect of Mo and SiC reinforced NiCr microwave cladding on microstructure, mechanical and wear properties. J. Inst. Eng. India Ser. D (2023). https://doi.org/10.1007/s40033-022-00445-8

    Article  Google Scholar 

  31. H.S. Nithin, K.M. Nishchitha, D.G. Pradeep, C. Durga Prasad, M. Mathapati, Comparative analysis of CoCrAlY coatings at high temperature oxidation behavior using different reinforcement composition profiles. Weld. World 67, 585–592 (2023). https://doi.org/10.1007/s40194-022-01405-2

    Article  Google Scholar 

  32. G. Madhusudana Reddy, C. Durga Prasad, G. Shetty, M.R. Ramesh, T.N. Rao, P. Patil, Investigation of thermally sprayed NiCrAlY/TiO2 and NiCrAlY/Cr2O3/YSZ cermet composite coatings on titanium alloys. Eng. Res. Express 4, 025049 (2022). https://doi.org/10.1088/2631-8695/ac7946

    Article  Google Scholar 

  33. C. Venkate Gowda, H. Hanumanthappa, B.K. Shanmugam, C. Durga Prasad, T.N. Sreenivasa, M.S. Rajendra Kumar, High-temperature tribological studies on hot forged Al6061-Tib2 in-situ composites. J. Bio Tribo-Corros. 8, 101 (2022). https://doi.org/10.1007/s40735-022-00699-5

    Article  Google Scholar 

  34. G. Madhusudana Reddy, C. Durga Prasad, P. Patil, N. Kakur, M.R. Ramesh, Elevated temperature erosion performance of plasma sprayed NiCrAlY/TiO2 coating on MDN 420 steel substrate. Surf. Topogr. Metrol. Prop. 10, 025010 (2022). https://doi.org/10.1088/2051-672X/ac6a6e

    Article  Google Scholar 

  35. G. Madhusudana Reddy, C. Durga Prasad, G. Shetty, M.R. Ramesh, T.N. Rao, P. Patil, High temperature oxidation behavior of plasma sprayed NiCrAlY/TiO2 & NiCrAlY/Cr2O3/YSZ coatings on titanium alloy. Weld. World (2022). https://doi.org/10.1007/s40194-022-01268-7

    Article  Google Scholar 

  36. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, A. Sarkar, High temperature gradient cobalt based clad developed using microwave hybrid heating. Am. Inst. Phys. 1943, 020111 (2018). https://doi.org/10.1063/1.5029687

    Article  Google Scholar 

  37. G. Madhusudana Reddy, C. Durga Prasad, G. Shetty, M.R. Ramesh, T.N. Rao, P. Patil, High temperature oxidation studies of plasma sprayed NiCrAlY/TiO2 & NiCrAlY/Cr2O3/YSZ cermet composite coatings on MDN-420 special steel alloy. Metallogr. Microstruct. Anal. 10, 642–651 (2021). https://doi.org/10.1007/s13632-021-00784-0

    Article  Google Scholar 

  38. M. Mathapati, K. Amate, C. Durga Prasad, M.L. Jayavardhana, T.H. Raju, A review on fly ash utilization. Mater. Today Proc. 50(5), 1535–1540 (2022). https://doi.org/10.1016/j.matpr.2021.09.106

    Article  Google Scholar 

  39. C. Durga Prasad, S. Lingappa, S. Joladarashi, M.R. Ramesh, B. Sachin, Characterization and sliding wear behavior of CoMoCrSi + Flyash composite cladding processed by microwave irradiation. Mater. Today Proc. 46, 2387–2391 (2021). https://doi.org/10.1016/j.matpr.2021.01.156

    Article  Google Scholar 

  40. G. Madhu, K.M. MrityunjayaSwamy, D.A. Kumar, C. Durga Prasad, U. Harish, Evaluation of hot corrosion behavior of HVOF thermally sprayed Cr3C2–35NiCr coating on SS 304 boiler tube steel. Am. Inst. Phys. 2316, 030014 (2021). https://doi.org/10.1063/5.0038279

    Article  Google Scholar 

  41. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, Microstructure and tribological resistance of flame sprayed CoMoCrSi/WC-CrC-Ni and CoMoCrSi/WC-12Co composite coatings remelted by microwave hybrid heating. J. Bio Tribo-Corros. 6, 124 (2020). https://doi.org/10.1007/s40735-020-00421-3

    Article  Google Scholar 

  42. R. Dinesh, R.S. Raykar, T.L. Rakesh, M.G. Prajwal, M. Shashank Lingappa, C. Durga Prasad, Feasibility study on MoCoCrSi/WC-Co cladding developed on austenitic stainless steel using microwave hybrid heating. J. Mines Met. Fuels 69(12A), 260–264 (2021). https://doi.org/10.18311/jmmf/2021/30113

    Article  Google Scholar 

  43. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, Comparative investigation of HVOF and flame sprayed CoMoCrSi coating. Am. Inst. Phys. 2247, 050004 (2020). https://doi.org/10.1063/5.0003883

    Article  Google Scholar 

  44. C. Durga Prasad, A. Jerri, M.R. Ramesh, Characterization and sliding wear behavior of iron based metallic coating deposited by HVOF process on low carbon steel substrate. J. Bio Tribo Corros. 6, 69 (2020). https://doi.org/10.1007/s40735-020-00366-7

    Article  Google Scholar 

  45. T. Naik, M. Mathapathi, C. Durga Prasad, H.S. Nithin, M.R. Ramesh, Effect of laser post treatment on microstructural and sliding wear behavior of HVOF sprayed NiCrC and NiCrSi coatings. Surf. Rev. Lett. 29(1), 225000 (2022). https://doi.org/10.1142/S0218625X2250007X

    Article  Google Scholar 

  46. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, B.H. Channabasappa, Comparison of high temperature wear behavior of microwave assisted HVOF sprayed CoMoCrSi-WC-CrC-Ni/WC-12Co composite coatings. Silicon 12, 3027–3045 (2020). https://doi.org/10.1007/s12633-020-00398-1

    Article  Google Scholar 

  47. M.S. Reddy, C. Durga Prasad, P. Patil, M.R. Ramesh, N. Rao, Hot corrosion behavior of plasma sprayed NiCrAlY/TiO2 and NiCrAlY/Cr2O3/YSZ cermets coatings on alloy steel. Surf. Interfaces 22, 100810 (2021). https://doi.org/10.1016/j.surfin.2020.100810

    Article  Google Scholar 

  48. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, B.H. Channabasappa, Effect of microwave heating on microstructure and elevated temperature adhesive wear behavior of HVOF deposited CoMoCrSi–Cr3C2 composite coating. Surf. Coat. Technol. 374, 291–304 (2019). https://doi.org/10.1016/j.surfcoat.2019.05.056

    Article  Google Scholar 

  49. K.G. Girisha, R. Rakesh, C. Durga Prasad, K.V. Sreenivas Rao, Development of corrosion resistance coating for AISI 410 grade steel. Appl. Mech. Mater. 813–814, 135–139 (2015). https://doi.org/10.4028/www.scientific.net/AMM.813-814.135

    Article  Google Scholar 

  50. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, B.H. Channabasappa, Development and sliding wear behavior of Co–Mo–Cr–Si cladding through microwave heating. Silicon 11, 2975–2986 (2019). https://doi.org/10.1007/s12633-019-0084-5

    Article  Google Scholar 

  51. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, B.H. Channabasappa, Microstructure and tribological behavior of flame sprayed and microwave fused CoMoCrSi/CoMoCrSi–Cr3C2 coatings. Mater. Res. Express 6, 026512 (2019). https://doi.org/10.1088/2053-1591/aaebd9

    Article  Google Scholar 

  52. C. Durga Prasad, S. Joladarashi, M.R. Ramesh, M.S. Srinath, B.H. Channabasappa, Influence of microwave hybrid heating on the sliding Wear behaviour of HVOF sprayed CoMoCrSi coating. Mater. Res. Express 5, 086519 (2018). https://doi.org/10.1088/2053-1591/aad44e

    Article  Google Scholar 

  53. K.G. Girisha, K.V. Sreenivas Rao, C. Durga Prasad, Slurry Erosion resistance of martenistic stainless steel with plasma sprayed Al2O3–40%TiO2 coatings. Mater. Today Proc. 5, 7388–7393 (2018). https://doi.org/10.1016/j.matpr.2017.11.409

    Article  Google Scholar 

  54. K.G. Girisha, C. Durga Prasad, K.C. Anil, K.V. Sreenivas Rao, Dry sliding wear behaviour of Al2O3 coatings for AISI 410 grade stainless steel. Appl. Mech. Mater. 766–767, 585–589 (2015). https://doi.org/10.4028/www.scientific.net/AMM.766-767.585

    Article  Google Scholar 

Download references

Funding

Not applicable.

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Atria Institute of Technology, Bengaluru, Karnataka, 560024, India

    C. Venkate Gowda & C. J. Manjunath

  2. Department of Mechanical Engineering, JSS Academy of Technical Education, Bengaluru, Karnataka, 560060, India

    T. K. Nagaraja & K. B. Yogesha

  3. Department of Robotics and Artificial Intelligence, Bangalore Institute of Technology, Bengaluru, Karnataka, India

    R. Prem Chand

  4. Department of Mechanical Engineering, Bangalore Institute of Technology, Bengaluru, Karnataka, India

    M. C. Manjunatha

  5. Department of International Institute for Aerospace Engineering and Management (IIAEM), Faculty of Engineering and Technology, JAIN (Deemed -to- Be University), Bengaluru, Karnataka, 560069, India

    Shrishali Sollapur

  6. Department of Mathematics, Reva University, Bengaluru, Karnataka, India

    N. Pushpa

Authors
  1. C. Venkate Gowda
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. T. K. Nagaraja
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. K. B. Yogesha
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. R. Prem Chand
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. M. C. Manjunatha
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Shrishali Sollapur
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. C. J. Manjunath
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. N. Pushpa
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to K. B. Yogesha.

Ethics declarations

Conflict of interest

The authors declare that they have no conflict of interest.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Venkate Gowda, C., Nagaraja, T.K., Yogesha, K.B. et al. Study on Structural Behavior of HVOF-Sprayed NiCr/Mo Coating. J. Inst. Eng. India Ser. D (2024). https://doi.org/10.1007/s40033-024-00641-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40033-024-00641-8

Keywords

Search

Navigation