Identifying the optimal HVOF spray parameters to attain minimum porosity and maximum hardness in iron based amorphous metallic coatings

Flow based Erosion – corrosion problems are very common in fluid handling equipments such as propellers, impellers, pumps in warships, submarine. Though there are many coating materials available to combat erosion–corrosion damage in the above components, iron based amorphous coatings are considered to be more effective to combat erosion–corrosion problems. High velocity oxy-fuel (HVOF) spray process is considered to be a better process to coat the iron based amorphous powders. In this investigation, iron based amorphous metallic coating was developed on 316 stainless steel substrate using HVOF spray technique. Empirical relationships were developed to predict the porosity and micro hardness of iron based amorphous coating incorporating HVOF spray parameters such as oxygen flow rate, fuel flow rate, powder feed rate, carrier gas flow rate, and spray distance. Response surface methodology (RSM) was used to identify the optimal HVOF spray parameters to attain coating with minimum porosity and maximum hardness.