Enhancing Wear Resistance of HVOF-Sprayed Coatings Using Partially Oxidized Powders

This book chapter discusses the impact of partial oxidation of NiCrBSiFe powders on the development of improved wear-resistant coatings. The partial oxidation process oxidizes alloy powders to a state in which approximately half of the substance is oxidized. The oxidation process developed a ceramic phase that added more hardness to the coating, enhancing its wear/abrasion resistance. Simultaneously, the metallic component of the powder helps to achieve both the necessary ductility and the lack of brittle fragility, and good adhesion to the substrate. This dual-phase structure removes the need for another bond coat, which is used in conventional coatings to provide better adhesion and load transfer. The partially oxidized layer of the coating offers better performance by merging the properties of ceramic and metallic alloys into a single layer of coating. Industries that demand components to withstand constant use and surface wear can benefit from this innovation. Applications of this technology include the manufacture of tooling, aerospace parts, automotive engine parts, and other engineering systems involving two mating surfaces under dynamic loads. By optimizing the oxidation level of the alloy powders, coatings can be produced with both the hardness and toughness tailored to meet industrial needs.