With appropriate process control, near-net-shape coatings can be successfully applied to parts with complex geometries using HVOF spraying and fine cermet powders. This study assesses the influence of critical process parameters on the deposition rate and properties of HVOF coatings produced using fine agglomerated WC-12Co powder (2-10 µm) with nanosized WC particles. Spray angle, standoff distance, gun velocity, track pitch, and backside air cooling pressure were varied during the experiments in order to determine their effect on coating hardness, roughness, and porosity as well as deposition efficiency. Variations in spray parameters were found to have a significant effect on deposition rate and coating properties.

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