Statistical Comparison of Processing Different Powder Feedstock in an HVOF Thermal Spray Process

Abstract Cermet coatings such as WC-Co and Cr3C2-NiCr are frequently applied by means of thermal spray processes to protect highly stressed surfaces against wear. The investigation the respective materials their coating properties in-flight particle often carried out in separate experiments. In this study, characteristics (hardness, deposition rate, porosity, thickness) (particle velocity temperature) three different WC-based powders a Cr 3 C 2 -NiCr powder processed an HVOF process investigated function some key parameters kerosene flow lambda, distance feeder disc velocity. These were varied within design experiments, whilst all other fixed. Both experiments plan settings fixed defined identically. statistically modeled influences compared. A well-selected, limited number experimental runs using statistical experiment (DoE) enable comparison. deployed models generalized linear with Gamma-distributed responses. show that temperature mainly depend on rate distance. However, case temperature, model coefficients for WC have signs, reflecting qualitative behavior.