Abstract
High-Sn bearing alloys have been used for more than a century in many areas of industry. They are typically applied by casting, although thermal spraying is gaining in use, particularly for component repairs. This study evaluates the effects of HVOF spray parameters on the velocity, temperature, size, and trajectory of Babbitt particles and correlates the in-flight characteristics with coating porosity and intermetallic phase distribution. In the experiments, Babbitt layers up to 370 μm thick were deposited on carbon steel substrates while measuring particle properties and deposition efficiency. Coating samples were analyzed by means of optical and electronic microscopy and some were chemically etched to reveal the size and distribution of intermetallic phases. Test results show a significant refinement in intermetallic phase distribution when compared with commercial flame and arc-sprayed coatings.
