Novel utilization of powder-suspension hybrid feedstock in HVAF spraying to deposit improved wear and corrosion resistant coatings

Deployment of a suspension feedstock has been known to alleviate problems associated with using sub-micron and nanosized powder for thermal spraying monolithic as well powder-suspension ‘hybrid’ composite coatings. However, hybrid never previously used in high-velocity air-fuel (HVAF) spraying. In this work, the very first time, chromium carbide (Cr3C2) co-sprayed along an Inconel-625 (IN-625) by HVAF process illustrative case study. Two variants IN-625 + Cr3C2 coatings were produced varying relative feed rates. For comparison, pure coating was also deposited utilizing identical spray parameters. Detailed microstructural characterization, porosity content, hardness measurement phase analysis as-deposited performed. The suspension-derived carbides retained bulk coating, resulting higher hardness. dry sliding wear test, demonstrated lower rate coefficient friction (CoF) compared conventional, powder-derived Furthermore, improved slightly increase content coating. Post-wear worn alumina ball debris performed understand mechanisms material transfer investigated potentiodynamic polarization corrosion resistance than conventional achieved, indicating that incorporation secondary, matrix did not compromise its performance. This work demonstrates novel approach incorporate any finely distributed second sprayed enhance their performance when exposed harsh environments.