Thermal spray WC-NiCr coatings generally requires grinding processing to meet the surface finish requirements. The cost associated with grinding can potentially be reduced through the deposition of finer (– 30 + 5 μm) feedstock rather than the more conventional commercial (– 45 + 15 or – 53 + 20 μm) feedstock. Additionally, such a fine powder is likely to require lower energy spray parameters, resulting in less heat input to the substrate, which could be beneficial in application on heat sensitive substrates. However, the spray parameters need to be optimised to mitigate increased degradation of coatings due to unacceptable brittleness caused by decarburisation and oxidation, and to produce defect-free dense coatings. In the present work, a theoretical model to optimise spray parameters was developed, which suggested an oxygen-to-fuel ratio slightly more than 3.3 and a shorter barrel to avoid decarburisation in coatings. In total four parameter sets suggested by the theoretical model were selected to spray the fine-cut powder using a 100 mm long barrel. Scanning electron microscopy, X-ray diffraction, microhardness, and 3Dprofilometer were used to analyse the produced coatings. The coatings deposited using optimised parameters exhibited the best performance in terms of low porosity, inter-splat cracks, brittleness, and roughness. Coating deposited at lower kerosine and oxygen flow rates, with reduced stand-off distance, was denser, crack-free, and ductile. Hence, the fine-cut powder can be used to produce a finer as-sprayed finish, thereby demonstrating the potential in reducing grinding efforts. Additionally, successful deposition of coatings using low energy parameters, making this an attractive option for thermally sensitive substrates.

A study was conducted into the use of HVOF coatings on hydraulic cylinder rods in marine environments subject to both biofouling and corrosion. The study comprised a laboratory phase for candidate material selection and HVOF process optimisation. This was followed by long term field testing of the most promising candidates, which were subsequently assessed based on corrosion, adhesion, surface roughness and hydraulic sealing performance. Two candidates, nickel based WC cermet coatings, WC–10Ni5Cr and WC–18Hastelloy C, showed excellent results, and are considered as candidates for the application.

This paper discusses the development of optimized processing windows for spraying high quality metal carbide-based coatings using advanced particle diagnostic technology. The cermet coatings are produced via the high velocity oxygen fuel spray process (HVOF) and are intended to be used in severe service applications such as marine hydraulics. To develop suitable coating process parameters, the traditional “trial and error” method is not technically robust, is costly and time consuming. Instead we investigated the use of real-time monitoring of parameters associated with the HVOF flame jets and particles using advanced in-flight particle diagnostics. Subsequently, coatings can be produced with knowledge concerning the molten particle size, temperature and velocity profile. The analytical results allow identification of optimized coating process windows, which translate to coatings of lower porosity and improved mechanical performance.