Thermal spray processes have been developing toward lower particle temperature and higher velocity. Latest generation high-velocity oxygen-fuel (HVOF) and high-velocity air-fuel (HVAF) can produce very dense coating structures due to the higher kinetic energy typical for these thermal spray processes. Thermally sprayed coatings usually contain residual stresses, which are formed by a superposition of thermal mismatch, quenching and, in case of high kinetic energy technologies, peening stresses. These stresses may have a significant role on the mechanical response and fatigue behavior of the coating. Understanding these effects is mandatory for damage tolerant coating design and wear performance. For instance, wear-resistant WC-CoCr coatings having high compressive stresses show improved cavitation erosion performance. In this study, comparison of residual stresses in coatings sprayed by various thermal spray systems HVOF (Thermico CJS and Oerlikon Metco DJ Hybrid) and HVAF (Kermetico AcuKote) was made. Residual stresses were determined through thickness by utilizing Tsui and Clyne analytical model. The real temperature and deposition stress data were collected in the coating process by in situ technique. That data were used for the model to represent realistic residual stress state of the coating. The cavitation erosion and abrasion wear resistance of the coatings were tested, and relationships between residual stresses and wear resistance were discussed.

中文翻译：

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残余应力评估及其对高动能 HVOF 和 HVAF 喷涂 WC-CoCr 涂层抗空蚀性的影响

热喷涂工艺已经朝着更低的颗粒温度和更高的速度发展。最新一代高速氧气燃料 (HVOF) 和高速空气燃料 (HVAF) 可以产生非常致密的涂层结构，因为这些热喷涂工艺具有较高的典型动能。热喷涂涂层通常包含残余应力，这是由热失配、淬火以及在高动能技术情况下的喷丸应力叠加形成的。这些应力可能对涂层的机械响应和疲劳行为具有重要作用。了解这些影响对于耐损伤涂层设计和磨损性能是必不可少的。例如，具有高压缩应力的耐磨 WC-CoCr 涂层显示出改进的空蚀性能。在这项研究中，对由各种热喷涂系统 HVOF（Thermico CJS 和 Oerlikon Metco DJ Hybrid）和 HVAF（Kermetico AcuKote）喷涂的涂层的残余应力进行了比较。残余应力是通过利用 Tsui 和 Clyne 分析模型通过厚度确定的。通过原位技术在涂层过程中收集实际温度和沉积应力数据。该数据用于模型以表示涂层的真实残余应力状态。测试了涂层的抗空蚀和耐磨性，并讨论了残余应力与耐磨性之间的关系。残余应力是通过利用 Tsui 和 Clyne 分析模型通过厚度确定的。通过原位技术在涂层过程中收集实际温度和沉积应力数据。该数据用于模型以表示涂层的真实残余应力状态。测试了涂层的抗空蚀和耐磨性，并讨论了残余应力与耐磨性之间的关系。残余应力是通过利用 Tsui 和 Clyne 分析模型通过厚度确定的。通过原位技术在涂层过程中收集实际温度和沉积应力数据。该数据用于模型以表示涂层的真实残余应力状态。测试了涂层的抗空蚀和耐磨性，并讨论了残余应力与耐磨性之间的关系。