Bulk, welded or laser cladded Stellite based materials are widely used in chemical industry due to their excellent combined properties against corrosion and wear processes and as a superalloy they have a high melting point and are designed to withstand high temperature for long periods of time. Problems related with poor inter-splat bonding arise when this kind of materials are sprayed with HVOF because it is characterized by having relatively low flame temperatures and high particle speed, and so dwell time may not be long enough to melt or soften Stellite particles completely. For these reasons, typical structured composed by a superposition of non-melted particles are obtained when spraying with propylene fuel gas. The aim of this work is to study the effect of using Hydrogen as a fuel gas and also to study the effect of the variation of the propylene flame characteristics. The coatings are characterized by SEM-EDS, XRD, and ASTM G99-90 sliding wear test has been done to compare the coatings. SWLI has been used to measure the volume lost after the wear test. Splat morphology studies have been also done in order to compare the melting behavior of the impinging particles.

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