A high velocity oxy-fuel spraying system using liquid fuel (HVOLF) has produced Stellite 6 (CoCrWC) and NiCoCrAlY coatings from gas atomised powders of both alloys. Comparative coatings were prepared by weld 0verlay (Stellite 6) and vacuum plasma spraying (VPS) of NiCoCrAlY. The original powders and coatings were characterised by Scanning Electron Microscopy (SEM) and X-ray diffraction (XRD). The presence or absence of cored dendritic microstructures in etched surfaces was used to interpret the degree of melting which took place during spraying, i.e. >80% in VPS and <20% in HVOLF. Low levels of oxide were formed in HVOLF coatings due to the reduced level of thermal transfer during the short heating cycle involved in spraying. For the same reason less melting occurred which permitted sufficient plastic deformation of the solid fraction to occur, reducing voidage between particles and then allowing the liquid fraction to weld them together. This pattern of short cycle heating with both NiCoCrAlY and Stellite 6 particles influenced second phase formation. In NiCoCrAlY coatings the β (Co Ni Al) phase remained as relatively coarse precipitates in the as - sprayed condition whilst in Stellite 6 little carbide eutectic formed. HVOLF spraying can produce coatings with different hardness values when compared with VPS coatings and weld overlays. This may widen the range of coating applications as well as reduce costs.

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