High Velocity Combustion Sprayed Coating Materials for Hard Chrome Replacement Applications

High velocity combustion thermal spray processes have focused on high velocity oxy fuel (HVOF) and more recently high velocity air fuel (HVAF). These processes are typically utilized to apply hard metal coatings for oil and gas, mining, and industrial wear applications, while HVOF has also found broader acceptance in other markets such as aerospace and power generation. In this work, a preliminary investigation of different material applicability to high velocity combustion coatings for hard chrome replacement is investigated. Process metrics, coating microstructure and wear/corrosion performance will be analyzed for coatings produced using varying feedstock powder types for the spray processes. Different primary carbide types and sizes, morphology as well as matrix composition will be evaluated for their applicability for hard chrome replacement as well as other relevant applications.