Optimizing HVOF Spray Parameters to Maximize Bonding Strength of WC-CrC-Ni Coatings on AISI 304L Stainless Steel
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JTTEE5 23:860–875 DOI: 10.1007/s11666-014-0091-4 1059-9630/$19.00 ASM International
Optimizing HVOF Spray Parameters to Maximize Bonding Strength of WC-CrC-Ni Coatings on AISI 304L Stainless Steel C. Thiruvikraman, V. Balasubramanian, and K. Sridhar (Submitted December 18, 2013; in revised form February 21, 2014) High velocity oxygen fuel (HVOF)-sprayed cermet coatings are extensively used to combat erosioncorrosion in naval applications and in slurry environments. HVOF spray parameters such as oxygen flow rate, fuel flow rate, powder feed rate, carrier gas flow rate, and spray distance have significant influence on coating characteristics like adhesion bond strength and shear strength. This paper presents the use of statistical techniques in particular response surface methodology (RSM), analysis of variance, and regression analysis to develop empirical relationships to predict adhesion bond strength and lap shear bond strength of HVOF-sprayed WC-CrC-Ni coatings. The developed empirical relationships can be effectively used to predict adhesion bond strength and lap shear bond strength of HVOF-sprayed WC-CrC-Ni coatings at 95% confidence level. Response graphs and contour plots were constructed to identify the optimum HVOF spray parameters to attain maximum bond strength in WC-CrC-Ni coatings.
Keywords
bond strength, high velocity oxy fuel spraying, optimization, response surface methodology, WCCrC-Ni coatings
1. Introduction WC-based cermet coatings are widely used to protect materials from erosion and corrosion because of their ability to resist wear and corrosion (Ref 1). It is generally believed that high velocity of spray particles and improved melting benefits the adhesion of a coating on to a substrate. High Velocity Oxy-Fuel (HVOF) spray process is characterized by a high flame velocity up to 2000 m/s. Such high velocity flame consequently results in the formation of spray particle stream with high velocity compared to conventional flame spraying and plasma spraying. Accordingly, HVOF spray process is a promising thermal spray process to deposit coatings with low porosity, consequently high density and higher bond strength (Ref 2, 3). Due to the high velocity associated with a relatively low flame temperature, HVOF process is suitable for producing cermet coatings of low porosity content (about 1%) with
C. Thiruvikraman, Department of Manufacturing Engineering, Annamalai University, Annamalainagar (P.O.), Chidambaram 608 002, India; V. Balasubramanian, Centre for Materials Joining and Research (CEMAJOR), Department of Manufacturing Engineering, Annamalai University, Annamalainagar (P.O.), Chidambaram 608 002, India; and K. Sridhar, Marine Materials Department, Naval Materials Research Laboratory (NMRL), Ambernath (P.O.), Thane 421 506, India. Contact e-mails: [email protected], [email protected] and sridsudi@ gmail.com.
860—Volume 23(5) June 2014
denser and less oxidized cermet coatings than other thermal spray methods with no significant thermal and mechanical alterations of the substrate (Re
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