In this work, wire arc spraying is used to produce coatings in which oil-filled capsules are incorporated in the metal matrix. The coatings were deposited on carbon steel substrates using commercially available Zn-Al and FeNiCr alloy wires. The capsules were injected almost radially toward the substrate using an independent slurry feeder. No signs of degradation were observed during spraying and the coatings were able to keep a low coefficient of friction. Wear tracks produced by the steel ball used for friction testing were examined and volume loss was determined based on wear track profiles.

Norway is a rich country endowed with many natural resources including hydropower, oil and gas, wind power, fish, etc. Norway has nowadays a high technological and research based industry. The discovery of the first oil field in 1969 has been the driving force for the Norwegian economy, accounting for nearly 50% of exports and 30% of state revenue. Since then several technology-based industries have been created and developed not only around the oil and gas business, but also in other fields such as the Aluminium production. Thermal Spray has played an important role in the Norwegian industry, where it has been used for more than 40 years in many different applications (corrosion and wear protection in the offshore industry, aeronautical industry, etc). The Norwegian thermal spray producers and users have a long tradition in collaborating and also working with R&D institutes such as SINTEF and Universities (specially the The Norwegian University of Science and Technology, NTNU) in order to develop new and better coatings. Based on this collaboration the Norwegian Thermal Spray Group was established in 1995 and since then it has grown constantly. The members of the group are: Bandak AS, Castolin Services, CerPoTech, GBSGroup, HCStarck, Mantena, Mets AS, Norwegian armed force logistic division (LHK), Powder Tec AS, Scana, SprayService AS, SubseaDesign, Teknologisk Institute, Trio AF, Volvo Aero Norge, SINTEF and the Norwegian University of Science and Technology. The group includes materials suppliers, coating producers, end users, education and certifying, research institutes and Universities. The aim of the group is to develop thermal spray activities in Norway and find new solutions for existing and new challenges in surface protection.

Problems with corrosion resistance in hydraulic cylinders used in marine environments contribute to many failures. Thermal spraying has proven to be a reliable method for replacing electroplated coatings in aircraft, but performance in high corrosive environments is still a drawback. In the present work, a new sealing method to densify WC-CoCr HVOF coatings is tested, which appears to be applicable to hydraulic cylinders in marine environments. The method is based on the use of nanoparticle solutions that penetrate and fill pores and cracks to seal the coatings. Two such solutions are tested and compared to as-sprayed coatings. Open-circuit potential and tribocorrosion measurements in 3.4% NaCl show that sealed coatings are more resistant to corrosion and wear than as-sprayed layers.

This paper reports on a structural characterisation of the nickel alloy coatings, before and after the fuse process is done and the main phases in each case, showing important differences between the nickel alloy coatings. Spray and fuse process involves thermal spraying to apply a coating of special self-fluxing alloys and a post thermal treatment at temperature between the solidus and liquidus of the alloy, when important diffusion processes take place. An improvement of the hardness and tribological properties is observed with the addition of tungsten carbide-cobalt to the nickel alloy powder. The results show the excellent tribological properties of the spray and fused coatings, better than the obtained for the as-sprayed coatings. The adhesion strength of the nickel alloy coating after the thermal treatment achieve a value above 80 MPa. Paper includes a German-language abstract.

This paper aims to characterise and to study several Ni-based alloys bond coatings and to determine the very best spraying conditions to achieve FGMs by means of a single gun with independent powder feed. First, adhesive layers made of NiCr, NiAl, and NiCrAlY were sprayed onto a steel substrate. All samples were tested by isothermal oxidation at 1000 deg C. The oxides formed and the conversions of the original oxides were studied on the samples and characterized using scanning electron microscope and EDS. It is observed that the study of three different bond coating sprayed with the same conditions reveals the best performance for the NiCr coating. Paper includes a German-language abstract.