Fe-based Powder Alloys Deposited by HVOF and HVAF for Applications Exposed to Solid Particle Erosion

Solid particle erosion is an important wear loading for a variety of applications such as pipelines for transport of granular materials, chemical/petrochemical process equipment, individual assemblies in mining, agricultural and construction equipment. Electrolytic hard chrome (EHC) plating is a cost effective solution for these applications. HVOF and HVAF spraying are considered as an alternative to EHC plating and other surface hardening technologies. The driving force is the cost efficiency of HVOF and HVAF spraying as well as environmental issues. Fe-based powder consumables for HVOF and HVAF spraying fit well with this requirement. This paper focuses on erosion resistance of three powder alloys using ASTM G76 particle impingement erosion testing to identify the possible wider use of these Fe-based powders. The paper includes a brief literature review, results of ASTM G76 erosion testing, microstructure and surface analysis of the test samples, discussion and conclusions considering applications exposed to solid particle erosion.