A Study of Cr3C2-Based HVOF- and HVAF-Sprayed Coatings: Microstructure and Carbide Retention

The research on high-velocity air-fuel (HVAF)-sprayed Cr3C2-based materials has mostly focused on conventional Cr3C2-25NiCr composition. In this paper, two alternative compositions (Cr3C2-50NiCrMoNb and Cr3C2-37WC-18NiCoCrFe) were sprayed with high-velocity oxy-fuel (HVOF) and HVAF spray processes to evaluate the material behavior during spraying and to provide characterization of the microstructures and mechanical properties of the coatings. For comparison, coatings from the Cr3C2-25NiCr composition were sprayed with both processes. Spray diagnostics were carried out to obtain average particle velocity and temperature for each material and process combinations. The measured average in-flight particle data were 1800 °C and 700 m/s for HVOF process, and 1450 °C and 900 m/s for HVAF process. Characterization of the coating microstructures was carried out by scanning electron microscopy and X-ray diffraction. In addition, the carbon content of the feedstock powders and sprayed coatings was measured with carbon analyzer. The results show that carbide rebounding or selective deposition of particles with higher metal matrix content is the dominating reason for carbide loss during HVAF spraying, while carbide dissolution is an additional source for the HVOF spraying. Higher particle velocities and controlled temperature measured for the HVAF process produced dense coatings with improved toughness and more homogenous coating structure.