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Effect of Deposition Rate and Deposition Temperature on Residual Stress of HVOF-Sprayed Coatings

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Abstract

In this paper, we examine the correlation between thermal spray process parameters that affect the deposition rate and the residual stress buildup in HVOF metallic and cermet coatings. Parameters of interest including feed-rate, raster speed, and substrate temperature (controlled via external cooling means) were evaluated in the context of their effect on the stress evolution in gas fuel HVOF-sprayed coatings. The process variables investigated are intended to change the deposition rate and subsequently the local deposition temperature (TLD) at the location of impact. The residual stress during the deposition tends to be more tensile with increased TLD, and this tendency is more significant when the change in TLD is produced by the feed rate. Compressive stresses result for lower TLD due to dominance of the peening effect. A systematic study of these effects was conducted for gas fuel HVOF-sprayed Ni- and WC-12%wt.Co-coatings. The Ni-coatings represent the family of ductile metallic materials, whereas the WC-12%wt.Co-coatings represent the behavior of hard cermets. Both materials develop compressive stress at low TLD and change into tensile stress at high TLD by manipulation of deposition rate parameters. Extensions to other materials and HVOF processes are also presented to support the analysis.

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Acknowledgments

This work was supported by the Industrial Consortium for Thermal Spray Technology. Collaboration and funding is gratefully acknowledged. Samples were deposited at facilies in Kennametal (before Deloro Stellite), PTI-Plasma Technology Industries, Caterpillar, Oerlikon Metco. We would also like to thank Dr. Roberto Rosa, Satish Dixit, and Michael Chin for his help in the spray experiments. Last, Alfredo Valarezo thanks the funding support from the “Chancellor Grants” from USFQ.

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Authors and Affiliations

  1. Materials Science and Chemical Engineering Department, Center for Thermal Spray Research, Stony Brook University, 130 Heavy Engineering, Stony Brook, USA

    Alfredo Valarezo, Kentaro Shinoda & Sanjay Sampath

  2. Department of Mechanical Engineering, IIMA-Institute of Materials Research, Universidad San Francisco de Quito, Diego de Robles y Vía Interoceánica, Campus Cumbayá, Quito, Ecuador

    Alfredo Valarezo

  3. National Institute of Advanced Industrial Science and Technology (AIST), 1-1-1 Higashi, Tsukuba, Ibaraki, 305-8565, Japan

    Kentaro Shinoda

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  1. Alfredo Valarezo
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Residual Stresses Credit Line: This article is part of a special topical focus in the Journal of Thermal Spray Technology on Advanced Residual Stress Analysis in Thermal Spray and Cold Spray Processes. This issue was organized by Dr. Vladimir Luzin, Australian Centre for Neutron Scattering; Dr. Seiji Kuroda, National Institute of Materials Science; Dr. Shuo Yin, Trinity College Dublin; and Dr. Andrew Ang, Swinburne University of Technology.

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Valarezo, A., Shinoda, K. & Sampath, S. Effect of Deposition Rate and Deposition Temperature on Residual Stress of HVOF-Sprayed Coatings. J Therm Spray Tech 29, 1322–1338 (2020). https://doi.org/10.1007/s11666-020-01073-y

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