Wall Colmonoy Ltd has developed a new generation of Iron-based powder alloys providing superior resistance to dry wear and excellent corrosion resistance. These alloys are economically interesting because they contain none or very low levels of expensive and market sensitive metals such as nickel and cobalt. These powders are marketed under the trade name Colferoloy. This paper details the properties and advantages of Colferoloy when compared to current “traditional” surface treatment methods and consumables. Metallurgical examination of the Colferoloy deposits showed that the alloy formed sub-micron structures which afford excellent dry-wear resistance, whilst the high chromium content provides good resistance to corrosion. Colferoloy alloys were applied using HVOF techniques to engineering components producing dense coatings with a hardness in the range of 950-1000 Vickers. The cost benefits of using an Iron-based alloy with low density hard phases were studied and comparisons with traditional materials were performed. This study showed that Colferoloy is a viable alternative to current hardfacing alloys and treatments.

Anilox rolls are ink-metering rolls used in the printing industry to transfer an exact amount of ink to the printing cylinder. The importance of high quality anilox rolls has increased with the demand for higher quality printing. Improvements of the characteristics of anilox rolls have been achieved mainly by using laser-engraved, ceramic-coated rolls rather than the common chrome-plated and mechanically engraved rolls. The best results concerning the ceramic coating of anilox rolls were achieved by Cr 2 O 3 coatings. These coatings require a bond coat for good corrosion resistance. By far the most-used technology to produce this bond coat is high velocity oxygen fuel (HVOF) spraying using NiCr material. In order to lower the cost of the anilox roll coating it has been investigated if NiCr can be replaced by the chromium steel 316L as bondcoat material. 316L was applied to the surface by HVOF. The characteristics of 316L / Cr 2 O 3 layers were compared with respect to the required quality of the coating. The results were 316L / Cr 2 O 3 coatings with good mechanical characteristics compared to NiCr / Cr 2 O 3 layers. In particular, the metallographic sections showed compact coatings having a tensile adhesive strength slightly higher than and a corrosion resistance similar to the coatings with a NiCr bond coat.