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"High velocity oxy-fuel (HVOF) sprayed tungsten carbide ? cobalt (WC-Co) coatings exhibit attributes that allow them to be a candidate material for high temperature applications; such as temperature insulators for rocket nozzles. This application note investigates the effect of surface preparation, in this case the grit blasting process, on the characteristics of the so-formed coating. The WC-Co coatings exhibited high hardness and low porosity. The composition of WC-Co coating varied in different regions, but on average was close to the composition of the initial feedstock, implying that there was no preferential loss of the material during the spray process.Microanalysis indicated diffusion of tungsten to the interface between the coating and the substrate and partly explains the high bonding strength of the coating. These physical characteristics suggest that the HVOF sprayed WC-Co is an appropriate coating technology for rocket nozzles."

"ABSTRAK

Thermal spray sering diaplikasikan pada leading edge bilah turbin uap untuk meningkatkan ketahanan abrasi. Stellite adalah salah satu material yang sering digunakan dikarenakan ketahanannya yang baik terhadap aus. Penelitian ini bertujuan untuk mengkomparasi properti metode flame spray, plasma spray, dan HVOF dalam mendeposisikan lapisan Stellite ke bilah turbin baja tahan karat martensitik 410. Hasil lapisan plasma spray dan HVOF menunjukkan deposisi lapisan yang rata sedangkan flame spray tidak. Ketiga proses thermal spray memenuhi spesifikasi kuat lekat minimum manufaktur. Rata-rata kuat lekat dan kekerasan tertinggi didapat dari proses HVOF dengan nilai masing-masing 33,1 MPa dan 719 HV. Berdasarkan standar deviasi kuat lekat dan kekerasan, proses HVOF memiliki hasil lapisan paling homogen. Kekerasan substrat di bawah antarmuka pasca proses pelapisan flame spray, plasma spray, dan HVOF masing-masing naik sebesar 236%, 56%, dan 65% dari spesifikasi substrat. Lapisan HVOF memiliki tampilan penampang yang paling baik. Persentase porositas, diameter porositas, dan rata-rata panjang unbonding terkecil didapat pada proses HVOF dengan nilai masing-masing 0,2%, 7,2 μm, dan 31%. Struktur mikro lapisan pasca pengetsaan menghasilkan fasa-fasa yang berhubungan dengan masukan panas. Struktur dendritik terbentuk pada lapisan proses flame spray dan plasma spray pasca pengetsaan, namun tidak pada proses HVOF. Oksida dan karbida kobalt maupun krom mungkin terbentuk pada lapisan.

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ABSTRACT

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Thermal spray is often applied on steam turbine blade leading edge to increase abrasion resistance. Stellite is one of the commonly used material as it is known to wear protection against abrasion, oxidation, and corrosion at elevated temperature. Thermal spray method generally used in industry are flame spray, plasma spray, and HVOF. This research is intended to compare properties of those methods in depositing Stellite coating on 410 martensitic stainless steel turbine blade. Plasma spray and HVOF coating show even deposition while flame spray coating not. Those three coatings meet manufacture minimum bond strength requirement. On the flame spray process, higher preheat temperature resulted in higher bond strength. Preheat temperature variation relatively not affect coating hardness. Highest average bond strength and hardness are got by HVOF process with a value of 4.799 psi (33,1 MPa) and 719 HV respectively. According to bond strength and hardness standard deviation, the HVOF process gives the most homogeneous coating. Substrate hardness just below the coating interface after flame spray, plasma spray, and HVOF process are raised by 236%, 56%, and 65% each from the specification. HVOF coating has the best cross section compared to others with little splat and porosity. Flame spray coating has the most significant and highest amount of porosity.  In terms of percentage and size, HVOF gives the best result with a value of 0,2% and 7,2 μm respectively. The smallest coating interface unbonding is got by the HVOF process, with an average of 31%. Flame spray, plasma spray, and HVOF coating microstructure after etching show phases related to heat input during application. The dendritic structure is observed on flame spray and plasma spray coating after etching but not on HVOF process. Oxides like Cr₂O₃, CoCr₂O₄, CoO, and carbides like CoC, Cr₇C₃, Co₆W₆C, or Cr₂₃C₆ probably formed in the coating based on EDS result. Moreover, chemical composition result also indicates the formation of silicon oxide on coating and iron oxide at the coating interface. 

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"Proceedings, 15th International Thermal Spray Conference Nice, France, 25-29 May 1998. The 271 papers presented in this two-volume set cover the theory of thermal spray, the properties of coatings, the different spraying processes, their quality control, and their practical application. The conference was organised by the Commissariat a l'Energie Atomique and five other French organizations, and was co-sponsored by the ASM Thermal Spray SocietySM, The German Welding Society, and the High Temperature Society of Japan. Contents: Oxidation, Wear, and Corrosion Jets and Deposits Properties and characterization Processes and Quality Control Applications Composite Structures Free-Standing Shapes Polymer Coatings Feedstock Spraying Thermal Barriers."

"Proceedings of the 1st International Thermal Spray Conference, Montreal, Quebec, Canada, May 8-11, 2000. Conference assembled nearly 300 experts from academia, research, and industry from 35 countries to discuss the challenges and opportunities facing the thermal spray community now and into the 21st century."

"Contents : - Quo Vadis Thermal Spraying ? - HVOF-Sprayed Quasicrystal Composite Coatings for Bearing Applications - Functional Ceramic and Metallurgical Coatings on Magnesium Components - Study on Zircon-Based Ceramic Coating for High Temperature Oxidation Resistant Application - Tungsten Coatings for Divertor Wings - Double Doped Ceria Electrolyte Synthesized by Solution Plasma Spraying with Induction Plasma Technology - Replacement for Hard Chrome Plating in Printing Machinery - A contribution to Engine pistons Life Time Improving by Means of Thermal Spray Coatings - Plasma Spraying of Tin on to a Monocrystalline Lithium Fluoride Window - Fabrication and Properties of TiO2 Plioto-Catalytic Coatings by Thermal Spraying with TiO2-AI Agglomerated Powder - XRD and Rietveld Quantitative Pliase Analysis of Radio Frequency Suspension Plasma Sprayed Nano-hydroxyapatite Powders - HVOF Sprayed Hydroxyapatite Coatings: Powders' Melting State and Mechanical Properties - In Vitro Changes on High-Pressure Plasma Sprayed Hydroxyapatite (HA) Caotings - Corrosion Resistant Coatings for Gas Turbine Exhaust Stack Applications - Ceramic Abradable Coatings for Applications up to 1100°C - Production of Superplastic Foils by Thermal Spraying - The Internal Plasma Spraying on Powerful Technology for the Aerospace and Automotive Industries - A Contribution to the Production and Characterization of HVOF coatings for Application in the Petrochemical Field - Process Modelling to Optimise the Structure of Hollow Zirconia Particles for use in Plasma Sprayed Thermal Barrier Coatings - Comparative Study of Different Sealing Methods for Thick Thermal Barrier Coatings - Influence of a Multi-Gas Mixture on the on the Performance of a HPPS Plazjet System for a Thermal Barrier Coating - Effect of Bond Coat Processes and Surface Characteristics on the Failure Mechanism of Thermal Barrier Coatings - Thermal Shock Characteristics of Functionally Graded Thermal Barrier Coatings - Kinetics of Thermally Grown Oxide at Interface Between Thermal Barrier Coatings and MCrAlY Bond Coatings - Reaction Diffusion Behavior of Thermally Sprayed MCrAlY Coatings on Ni-Based Super Alloys - Optimization of Shop Practices for Thermal Barrier Coatings - Removal of Thermal Barrier Coatings from Turbine Blades: A Comparison of Machanical and Chemical Methods - Induction Plasma Synthesis of MoSi2 Ultrafine Powders - Improvements in HVOF Sprayed Cermet Coatings Produced from SHS Powders - Composites Made of Metal Foams With Thermally Sprayed Coatings - Plasma Spray Dissociation ZrSiO4 As The Basis of Forming ZrO2-Mullite Composites from a ZrSiO4 + AI2O3 Mixture - HVOF Sprayed Hydroxyapatite/Titania Composite Coatings - Manufacture of SiC Composite Coatings by HVOF - Hight Temperature Behaviour of Plasma Sprayed ZrB2-SiC Composite Coatings - Abradable Coatings for Low-Temperature Applications - Developments of Plasma Sprayed Ceramic Coatings - Properties of Al203 coatings sprayed by HFPD - On the Tailoring of Spray Dried Thermal Spray Powders - Spray Powders and Coatings on the Basis of Titanium Suboxides - A Comparative Study of the Deposition of Chromium Carbide Based Metal Matrix Composites by Axial Plasma Spray, Air Plasma Spray and High Velocity Oxygen Fuel - Heating Effect of Flame Impingement on polymer Coatings - Mechanical Properties of Thermal Spray PEEK Coatings - Characterization and Mechanical Properties of Flame Sprayed Hydroxyapatite/Polymer Composite Coatings - Structure and Thermal Conductivity of Flame Sprayed Polyamide 11 Coatings Filled with AI2O3, AIN and BN Ceramics - Surface Modification of Recycled PET Plate by Particle Implantation and Deposition with Plasma Spraying - Sprayed Composite Coating of High Performance Thermoplastics - Processing and Characterization of Nanostructured Cermet Coatings - Synthesis and Properties of Multimodal WC-12 Co Coatings - Structure and Properties of HVOF Sprayed Amorphous Polymer Matrix Nanocomposite Coatings - Properties of HVOF Sprayed Multi-Scale Polymer/Silica Nanocomposite Coatings - Control of the Injection of an Alumina Suspension Containing Nanograins in a dc Plasma - Cold Sprayed Nanostructured WC-Co - Low Pressure Plasma Spraying of Sol-Gel Al203/SiC Nanocomposite Coatings - Effects of Shock Waves on Impact Velocity of Cold Spray Particles - Optimization of the Cold Spray Process - Kinetic Powder Compaction Applying the Cold Spray Process A Study on Parameters - Experimental Study of Interaction of Supersonic Gas Jet With a Sub"

"Thermal spray is a coating process that provides functional surface to protect or improve the performance of a substrate or component. Almost any kind and form of material can be thermally sprayed which is why thermal spray is used worldwide to provide protection from corrosion, wear, and heat, to restore and repair components, and for a variety of other applications. This reference handbook is the complete guide to thermal spray technology. It covers principles, processes, types of coatings, applications, performance, and testing/analysis. Developed under the guidance of the Thermal Spray Society Training Committee, the handbook provides an excellent introduction and guidebook for those who are new to thermal spray. It also provides enough in-depth coverage and data that it should be of great value to specifiers and users of thermal spray coatings and to thermal spray experts who need additional background in certain areas."

"Contents : - Numerical and Microstructural Investigations of the Bonding Mechanisms in Cold Spraying - High Strain Rate Deformation Phenomena in Explosive Powder Compaction and Cold Gas Spraying - Optimizing the Cold Spray Process - Modeling of Particle-Substrate Adhesive Interaction Under the Cold Spray Process - A Systematic Approach to Material Eligibility for the Cold Spray Process - Particle-Substrate Interactions in Cold Gas Dynamic Spraying - Evaluation Of Coatings Produced Via Kinetic And Cold Spray Processes - Potential Applications of Cold-Spray Technology in Automotive Manufacturing - Development of Cold Gas Sprayed Coatings - Cold Spray Copper Application for Upper Stage Rocket Engine Design - Kinetic Spray of Aluminum Metal Matrix Composites For Thermal Management Applications - Effect of Spray Angle on Deposition Characteristics in Cold Spraying - Cold Spraying – Equipment and Application Trends - Automated Cold Spray System: Description of Equipment and Performance Data - Helium Recovery: Design Considerations for Cold Spray Systems - Cold Spray Technology: An Industrial Perspective - Production Coating Cost Comparison - Thermal Spray Solutions For Diesel Engine Piston Rings - Low-Cost High-Performance Coatings Produced by Internal Plasma Spraying for the Production of High Efficiency Engines - Development of Thermal Spray for Automotive Cylinder Bores - 316L – an Alternative to NiCr Bondcoats for Cr2O3-Coatings on Anilox Rolls - Plasma-Sprayed Ceramic Coatings for Molten Metal Environments - Influence of Powder Size in Aluminum Oxide Coatings for Use in the Semiconductor Industry - Intermediate Temperature SOFC Based on Fully Integrated Plasma Sprayed Components - Investigation of the Photocatalytic Efficiencies of Plasma Sprayed Tio2-Fe3O4 Coatings - Protection of Titanium Alloy Surfaces by Thermal Spraying and Laser Treatment - Fabrication of TiO2 Photocatalytic Coatings on PET by Thermal Spraying - Photocatalytic Decomposition of Ammonia by Thermal Sprayed TiO2 Coatings - Optimization of Axial Injection Conditions in a Supersonic Induction Plasma Torch: Application to SOFCs - Methodology for Meeting Standards and Environmental Requirements in Thermal Spraying Hardfacing and Sand Blasting Erosion Resistance of Arc Spray Composite Coatings at High Temperature on Boiler Tubes of Pulverized Coal Fired Power Station - Assessing the Feasibility of Using Diamond as a Reinforced Phase in Metal Matrix Composite Coatings - New Carbide Based Materials for HVOF Spraying - Advanced Oxide Ceramic Coatings for Applications Demanding High Wear Resistance - Development and Application of WC-Cr3C2-Ni Coating with High Impact Resistance - Preparation and Characterization of Powders and Coatings Containing Solid Lubricants - Properties of Plasma and D-Gun Sprayed Metal-Matrix-Composite (MMC) Coatings Based on Ceramic Hard Particle Reinforced Fe-, Ni-aluminide Matrix - Ceramic Coating of Alloy 625 using Controlled Atmosphere Plasma Spraying for Sea Water Corrosion Protection - The Influence of Matrix Phase Viscosity on the Plasma-Spray Deposition Of Silicon-Nitride Composite Coatings - Influence of Rare Earth Elements on the Corrosion Resistance of Fe-Cr-Ni Thermal Sprayed Coatings - Process Temperature-Hardness-Wear Relationships for HVOF-Spraye Nanostructured and Conventional Cermet Coatings - A Parametric Study of an HVOF Process for the Deposition of Nanostructured WC-Co Coatings - Abrasion and Sliding Wear of Nanostructured Ceramic Coatings - Fatigue and Fracture Resistance of Nanostructured Composite System: Chrome Carbide – Hard Oxide Aluminum – Aluminum - Abrasion Wear Behaviour of Plasma and HVOF Sprayed Al2O3-SiC Nanocomposite Coatings - Effect of Powder Composition on the Microstructure and Wear Properties of Sprayed Cast Iron Coatings - Influence of Thermal Spray Process on the Corrosion Behavior of High-Density - Stainless Steel Coatings in Simulated Marine Environment - A New Spray Coating Process for Manufacture of Stainless Steel Clad Construction Steel with Resistance to Corrosion by De-icing Salts & Seawater - HVOF Reactive Spraying of Mechanically Alloyed Ni-Ti-C Powders - Marine Exposure Tests of Thermal Sprayed Coatings in Japan - Development of Dense Corrosion Resistant Coatings By an Improved HVOF Spraying Process - Protection of Steel Components Against Marine Corrosion by Thermally Sprayed Anodic Coatings - Development and Implementation of HVOF WC/Co/Cr Coating as Alternative to Electrolytic Hard Chrome Plate in Landing Gear Applications"

"This proceedings volume representing the second International Thermal Spray Conference (May 2004, Osaka, Japan) contains 232 papers and 93 poster presentations. Arrangement is in sections on applications, characterization methods for coating properties, coating technologies for vehicle engines, cold spray, consumables for thermal spraying, corrosion protection, economics and quality, HVOF processes and materials, innovative equipment and process technology, modeling and simulation, nanostructured materials, photocatalytic materials, process diagnostics, protective coatings against wear and erosion, and thermal barrier coatings."