Professional Documents
Culture Documents
GUIDELINES ON THE
SPECIFICATION AND USE OF
HVOF COATINGS
Report to:
JSF ESOH Working Group
Date: March 28, 2006
Keith Legg
John Sauer
Bruce Bodger
Contact information:
Dr. Keith O. Legg
Rowan Technology Group, 1590 South Milwaukee Ave, Suite 205, Libertyville, IL 60048
Tel: 847-680-9420, Fax: 847-680-9682
Email: klegg@rowantechnology.com
ii
PREFACE
This document is designed as a set of guidelines for the design engineer,
covering the requirements, specifications and issues involved in
designing for the use of HVOF in place of hard chrome. The basic
information is written into the document, with additional information,
illustrations, and links to detailed summaries, reports and explanations.
Detailed additional data and reports are available on the web.
Page iii
Page iv
TABLE OF CONTENTS
Preface ........................................................................... iii
Table of Contents ........................................................... v
List of Tables ................................................................. vi
List of Figures............................................................... vii
Summary ........................................................................ ix
1.
Introduction ................................................. 1
2.
2.1.
2.2.
2.3.
Equipment ......................................................................... 5
2.4.
Powders ............................................................................ 6
2.5.
2.6.
2.7.
3.
3.1.
3.2.
3.3.
3.4.
Typical QC requirements................................................. 13
3.5.
4.
4.1.
4.2.
Run-out requirements...................................................... 16
4.3.
Finishing .......................................................................... 17
4.4.
Typical Applications......................................................... 19
Page v
4.5.
4.6.
4.7.
5.
5.1.
5.2.
5.2.1.
5.2.2.
Optimization ..................................................................... 23
5.2.3.
5.2.4.
5.2.5.
5.2.6.
5.2.7.
Masking............................................................................ 26
5.3.
NDI .................................................................................. 27
5.4.
5.4.1.
Repair............................................................................... 31
6.
ESOH .......................................................... 32
7.
Performance .............................................. 33
7.1.
Properties Summary........................................................ 33
7.2.
References .................................................................... 36
LIST OF TABLES
Table 2-1. Types of thermal spray processes..................................... 5
Table 2-2. Mesh vs powder size. ........................................................ 6
Table 2-3. Comparison of HVOF and chrome plating......................... 8
Table 3-1. HVOF specifications in use in the aircraft industry. ........... 9
Table 3-2. HVOF class and powder type definitions (AMS 2447 and
BAC 5851). Primary build-up and wear resistant coatings shown
with yellow background. ............................................................. 10
Page vi
LIST OF FIGURES
Figure 2-1. HVOF gun ........................................................................ 2
Figure 2-2. HVOF spray of landing gear inner cylinder (Southwest
United Aeroservice). The cylinder spins while the gun traverses
back and forth along it. ................................................................. 3
Figure 2-3. Typical thermal spray booth and associated equipment
(Progressive Technologies).......................................................... 4
Figure 2-4. HVOF WC-10Co4Cr cross sectional microstructure (D.
Dudzinski, NRC IAR). ................................................................... 7
Figure 4-1. HVOF runout typical Boeing requirements.................. 17
Figure 4-2. Runout at journal edge ................................................... 17
Figure 4-3. Overlay of Cd on HVOF typical Boeing requirements. 20
Figure 5-1. Temperature excursions during spraying (Sauer and
Sahoo3)....................................................................................... 25
Figure 5-2. Principle of the shadow mask......................................... 26
Figure 5-3. FPI indications on HVOF coatings ................................. 29
Figure 5-4. Barkhausen noise indication over grind burn standard. . 30
Page vii
Page viii
SUMMARY
HVOF coatings are increasingly specified in place of hard chrome
plate, for wear resistance on original equipment as well as for
rebuilding worn or corroded components.
HVOF Process
Line-of-sight Good for external surfaces and internals whose
depth is not much larger than their diameter
Materials Able to deposit hard carbide and other ceramicmetal composites for wear resistance and alloys for
dimensional restoration
Temperature Can keep temperature <375F for high
strength steels, and lower for Al alloys
Performance
Wear rate usually <1/3 that of hard chrome
Corrosion in service <hard chrome (but ASTM B117 salt fog
usually shows more corrosion than chrome)
Hydrogen embrittlement none
Environmental embrittlement <hard chrome (ASTM F519)
Abusive grinding generally more difficult to burn
Stress Coatings >0.003 thick (75m) can spall if stressed to
near high strength steel yield point.
NDI
Fluorescent penetrant (FPI)
Barkhausen (Roll Scan) for grind burns
Critical requirements
Thickness Minimum 0.001 (25m), maximum 0.020
(500m) for carbides, much thicker for alloy coatings
Finish Up to 125 Ra for wear / roller applications; <6 Ra
(0.15 m) in seal applications (hydraulics, landing gear, etc.); 8
16 Ra for most other applications. May need to define Rz,
Tp, or other parameters, especially for seal applications.
Coating edge Avoid sharp-edged coatings, which can chip
and may cause stress risers or damage seals during
installation or assembly.
Specifications
AMS 2447 (General), AMS 2448 (For use on High Strength
Steel), AMS 7881 (WC-Co powder), AMS 7882 (WC-CoCr
powder), BAC 5851 (General)
Page ix
Page x
1. Introduction
The purpose of this document is to provide the basic information
required by design and repair engineers who need to specify HVOF
coatings. While thermal spray specifications cover the process, these
guidelines are intended to provide the details that are generally not
found in specifications, as well as providing information on the
limitations and pitfalls of the process.
These guidelines are designed as a succinct reference work, with
more detail provided in attached documents and references. We
assume that the user has some level of familiarity with the HVOF
process, and the various plating processes it will replace, although
references and attached documents are provided to give more detail
to those unfamiliar with it.
Notes:
We will endeavor to maintain the document current, but since
usage of HVOF coatings is expanding rapidly some of the data
and information on usage may become out of date.
It is assumed that the primary purpose for the use of these
guidelines is replacing hard chrome plate plating for both new
design and repair.
It is important that the coating and finishing be done by
qualified providers since coating and finishing are specialized
processes.
These are guidelines, not specifications, and different OEMs
and vendors may use their own specifications that are different
from the typical specifications discussed here.
A wealth of information on the performance and usage of
aerospace HVOF coatings is available on the passwordprotected sections of the following web sites.
Sources of information:
www.hazmat-alternatives.com This is a portal into alternatives to
reports, briefings and data on an increasing number of hazardous
materials and processes, currently including hard chrome, cadmium
and chromates.
www.materialoptions.com This is the Hard Chrome Alternatives
Team (HCAT) teaming website that contains detailed reports, raw
data, and briefings of all HCAT meetings.
Passwords and assistance with finding information are available from
Keith
Legg,
Rowan
Technology
Group,
847.680.9420,
klegg@rowantechnology.com.
Page 1
2. Process fundamentals
For detailed information on HVOF as a hard chrome replacement for
the aerospace industry see Use of Thermal Spray as an Aerospace
Chrome Plating Alternative, a summary developed for the JSF ESOH
IPT 1 .
All HVOF guns work essentially the same way, with the primary
difference being in the fuel used and the overall gun power and
deposition rate. The flame is supersonic (as evidenced by the
supersonic shock diamonds that can always be seen in the flame).
The powder particles in the flame are typically heated from 2,900 to
Page 2
3,600F (1,600 to 2,000C), and are accelerated to about 1,200 1,600 mph (550 - 700 ms-1), well above Mach 1.
The HVOF spray process is done in a very similar way to paint
spraying. The hot particles come out of the gun in a narrow stream,
which must be moved back and forth to cover the whole surface
uniformly. For typical aerospace components such as landing gear or
hydraulics, which are cylinders, the part is rotated and the gun moved
up and down, usually using an industrial robot. The part to be
sprayed is usually placed on a horizontal table so that it rotates
vertically, or it is held in a lathe and rotated horizontally, while the
robot arm moves the gun back and forth uniformly, sometimes
pausing with the spray running off the part to allow it to cool down.
Figure 2-2. HVOF spray of landing gear inner cylinder (Southwest United
Aeroservice). The cylinder spins while the gun traverses back and forth
along it.
Figure 2-2 shows a landing gear inner cylinder being HVOF sprayed
with WC-Co. The cylinder is 2-3 feet long and 3 or 4 inches diameter.
The flame is the bright yellow streak coming from the gun at the lower
right and the color difference shows the coating building up. With the
cylinder rotating the gun has started at the left and is traversing to the
right. Spraying the entire cylinder to a thickness of 0.010 (250m)
will take about half an hour. The ends of the area to be sprayed are
covered with a hard mask, which is a cylindrical cover that prevents
the spray coating beyond the working stroke while ensuring proper
runout.
Page 3
Figure 2-3. Typical thermal spray booth and associated equipment (Progressive
Technologies).
Page 4
Process
Material
sprayed
Heat
source
Comments
HVOF
Powder
Detonation
gun
Powder
Fuel
explosion
Flame spray
Powder
Subsonic
flame
Plasma
spray
Powder
Plasma
Wire arc
spray
Wire
Electric arc
Cold spray
Powder
None or
warm gas
2.3.Equipment
There are currently three major equipment manufacturers in the
HVOF aerospace market (although there are several newer
manufacturers now entering the market):
Sulzer Metco DiamondJet (DJ) system
o
Page 5
2.4.Powders
Table 2-2. Mesh vs powder
size.
Mesh
Micron
Microinch
120
125
5,000
140
105
4,100
170
90
3,600
200
74
2,900
230
62
2,300
270
53
2,100
325
44
1,700
400
37
1,500
625
20
800
1250
10
400
2500
200
Micron 15,000/mesh
2.5.Coating parameters
Generally it is reasonable to use the standard spray shop process,
absent any particular reason for choosing an alternative. However, it
is very important to be sure that the process chosen has been
developed for the type of application you are using (see Section
5.2.2). If, for example, a process usually used by the supplier for
coating non-fatigue-critical parts for wear
resistance is used
unchanged to coat fatigue-sensitive aircraft parts, you may have a
large fatigue debit because the hardest wear coatings happen to have
a tensile internal stress. So you should be sure that both the powder
and the coating process match your application and that the supplier
Page 6
2.6.Coating structure
Page 7
Chrome plate
HVOF
Coating process
Process complexity
Complexity of parts
that can be coated
Coating material
Cr
Wear resistance
Good
Brittleness
Little ductility
Bond strength
Excellent. Metallurgical
bond. Requires proper
surface activation
Corrosion
resistance
Fair
Grinding
Diamond wheel
Finishing
Seals
Elastomeric, PTFE
NDI
FPI, Barkhausen
Page 8
Specification
Source
Notes
AMS 2447
SAE, 1998
AMS 2448
SAE, 2004
AMS 2449
SAE, 2004
AMS 7881
SAE, 2003
AMS 7882
SAE, 2003
BAC 5851
Boeing
BMS 10-67
Boeing
BAC 5855
Boeing
Lockheed
Hamilton
Sundstrand
HS 4412
Page 9
Table 3-2. HVOF class and powder type definitions (AMS 2447 and BAC 5851). Primary
build-up and wear resistant coatings shown with yellow background.
Class
BAC
5851
Type
AMS
2447
Type
Powder chemistry
Plasma spray
HVOF
II
III
IV
VI
Nickel-Chrome (Ni-20Cr)
5
VII
VIII
IX
XI
XII
Nickel-Aluminum (Ni-5Al)
XIII
XIV
XV
XVI
3
XVII
XVIII
10
Page 10
3.2.Definitions in a typical
specification
Typical HVOF specifications define the process in such a manner as
to ensure reproducibility. While some companies specify the process
by the coating performance, others specify the precise coating
conditions, including the coating booth in which it is to be done.
In calling out an HVOF coating it is necessary to specify the following:
1. process conditions (including maximum allowed temperature)
2. powder to be used
3. allowable substrate temperature
4. surface finish
5. QC and QA requirements.
If the coating is to be specified by performance, the following property
and performance specs will normally be necessary:
Manufacturers spray gun and powder designations
Thickness (usually 0.003-0.005 for OEM coatings and up to0.015) for MRO
Adhesion (ASTM C633 bond strength) > 10ksi (i.e. glue failure
before coating bond failure)
Residual stress (usually defined by Almen strip)
Hardness (Vickers)
Porosity (defined by metallographic cross section of witness
specimen).
Allowable percentage of unmelts and oxides (defined by
metallographic cross section of witness specimen).
Depending on the application one or more qualification tests
may also be required. For example, Boeing requires vendors
to pass a fatigue test.
If the coating is to be specified by deposition conditions, then,
in addition to the above requirements the deposition conditions
will be specified, often including
o
Maximum and
excursions
minimum
substrate
temperature
Page 11
Page 12
3.4.Typical QC requirements
Table 3-3. Commonly used Quality Control tests.
Method
General Description
Hardness
Tensile
Residual
stress
Almen N strip
Temperature
monitoring
Surface
roughness
Metallography
Description
Interface
contamination
Porosity
Oxides
Unmelted
particles
Phase content
Cracks
and Parallel to interface or through coating
delaminations
Booth release Before spraying commences for the day it is
customary to require the spraying of a booth release coupon, which is
evaluated prior to commencing spraying and retained for future
reference.
Witness specimens One or more witness specimens may be
attached to either an uncoated area of the component or to the
fixturing adjacent to the component, so that it receives the same
coating as the component, for metallographic analysis and retention.
Almen specimens Almen N strips, which are designed for
measuring shot peen intensity, are also used for measuring coating
stress.
Specifications for coating fatigue-sensitive components
usually require a compressive Almen range. Note: Compressive
Almens can be achieved with HVOF carbides, but not usually with
alloy coatings.
Page 13
3.5.Qualified Processors
Aerospace-qualified vendors may be found in most parts of the world.
As is the case with most controlled processes, Aerospace OEMs
include a Qualified Processors List as an attachment to their coating
specifications. If direct interaction with a prospective supplier is
desired, contact your Vendor Quality Department and request a copy
of the list produced by your Company.
It is very important that the thermal spray processor be a qualified
vendor familiar with processing the types of components used for your
application.
Page 14
Application
Notes
Sharp edged
coating
Plunge
ground O-ring
groove
Wear coating
into groove,
hole or sharp
corner
Centerless
grinding
Sealing
surfaces
Deep
internals
Internal
corners
Page 15
4.2.Run-out requirements
Warning: HVOF
coatings with sharp
edges will chip.
Runout must be
properly specified.
Do not run coatings
over edges of
journals, pins, holes,
etc.
Page 16
4.3.Finishing
Warning: HVOF
carbide coatings
must be finished with
a diamond wheel or
tape. Avoid centerless grinding.
Page 17
since most coated components are steels that are finished with
alumina or carbide wheels. For example, plunge grinding of carbide
coated steel to form an O-ring groove is not possible. Even it were,
the coating edge would chip. Methods of finishing steels with
diamond wheels have been developed by companies that frequently
grind HVOF coatings.
Superfinishing: For sealing applications HVOF coatings are usually
superfinished (vibrating stone or tape). Superfinishing gives a cleaner
surface with less debris than grinding alone. The aim is to achieve a
finish with flat bearing areas interspersed with controlled grooves for
oil retention 2 .
Table 4-2. Typical HVOF finishes.
Application
Finish
Comments
Non-sealing
roller Ra = 125
surfaces, tracks, etc
Light polish
Non-sealing surfaces Ra = 8
journals, static seals
Ground
Superfinished. Some
users specify finish
with a number of
finish parameters.
Tp = 50-85% at 8
Note: Carbides can be superfinished to <2, but Tribaloy coatings
have higher porosity and cannot take a finish <12.
For example, Greene, Tweed specifies the following for HVOF coated
dynamic seal surfaces (such as hydraulic rods) using ACT Ring
seals 3 :
Ra = 4-8 max
Rz = 50 max
Rp = 24 max
Tp = 50-70% at depth of p=0.25 Rz relative to line c=5% Tp
Page 18
4.4.Typical Applications
HVOF material,
BAC 5851 Type
Substrate
alloy
Finish
Notes
Landing gear
inner cylinder OD
300M, A100
Superfinish <4 Ra
Landing gear
bearing journals
300M, A100
Grind 8-16 Ra
Landing gear
outer cylinder ID
300M, A100
Superfinish <8 Ra
Hydraulic cylinder
rod OD
15-5PH,
4340
Superfinish <4 Ra
Hydraulic cylinder
ID
15-5PH,
4340
Grind or superfinish
<4 Ra
Hydraulic cylinder
piston OD
15-5PH,
4340
Grind or superfinish
<4 Ra
Bearing journals
(landing gear,
actuators,
engines)
15-5PH,
4340, 300M,
A100
Grind 8-16 Ra
Type I (WC-Co)
Ti alloys
As-sprayed, 125150 Ra
Other wear
surfaces
Various
Grind or superfinish
4-16 Ra
Build-up
All
As-sprayed
Quite soft, low stress. Often use buildup coating with carbide cap (equivalent
approach to hard Cr on sulfamate Ni)
Page 19
Warning: Never
deposit HVOF
coatings on top of
other coatings,
especially
cadmium.
Page 20
Page 21
4.7.Configuration control
HVOF coatings are overhauled differently from hard chrome coatings.
Although freshly-sprayed HVOF coatings are usually somewhat
darker than hard chrome, it is not easy to tell which coating is on a
component. (After a year or two in the field, HVOF WC-Co exposed
to the elements usually develops a light gray patina, making it easier
to distinguish.) For this reason, if a changeover is made on an
existing part from hard chrome to HVOF, thought must be given to
configuration control and to ensuring that the coating is obvious to
maintainers. Most users develop dash numbers, although some
change the part number. Others have, in addition, applied a highlyvisible paint spot to alert maintainers.
Page 22
Coating thickness
Coating temperature
Masking
Run-out at end of
coating
Finishing
Witness specimens
Warning: HVOF
coating deposition
parameters must be
optimized for the
application in which
they are to be used.
5.2.2. Optimization
Most aerospace-qualified coating vendors spray according to specs
developed for existing customers. Usually this will be adequate,
provided they are aerospace customers and the coating is optimized
for the same application. E.g. a coating optimized for wear resistance
will not be optimized for fatigue. If fatigue is critical the coating must
be re-optimized for fatigue.
Page 23
Page 24
Figure 5-1.
Sahoo4).
Surfaces are usually grit blasted to create the correct surface profile
for coating adhesion and for cleanliness. Grit blasting requirements:
Grit blast after shot peening
High strength steels 24 grit, 40-60 psi, 100% coverage
Ti and Al alloys and other soft alloys Avoid embedding grit at
surface by blasting at an angle and at lower pressure.
Parameters may need to be optimized.
Page 25
5.2.7. Masking
Masking is used to prevent unwanted coating in various areas. Types
of mask:
Waxes and tapes
cannot be used
Warning: Tapes and
waxes cannot be
used with HVOF.
Hard metal masks
are required.
Fabricated
hard
mask for commonly
coated parts hard
masking is usually
machined from steel
to prevent coating
onto
unwanted
areas.
Shadow mask used
to control runout.
Hard mask or shim
set 1 or so from
surface to create
specified
runout
(Figure 5-2). Correct
shadow mask setting
depends on gun
plume divergence.
Figure 5-2.
Companies
exist
that mask.
specialize in the design and
construction of thermal spray hard masking.
Page 26
5.3.NDI
Table 5-1. NDI inspection methods for HVOF coatings.
Warning: MPI
cannot be used for
HVOF. Use FPI for
surface damage, and
Barkhausen Noise
for grind burn
detection.
Method
Types of defect
Notes
Fluroescent Dye
Penetrant
Inspection (FPI)
(ASTM E1417)
Post-grinding cracks,
pits, pullouts,
spiraling. In-service
cracks, scratches,
chips, delamination
Level 3 or 4 may be
needed for detection of
fine cracks
Visual (white
light) inspection
Barkhausen noise
(Rollscan)
Abusive grinding
burns
Similar detectability
beneath coating as with
hard chrome. Use same
specs as chrome.
Magnetic Particle
inspection (MPI)
NONE
Magnetic Particle Inspection is not a viable technique with HVOF WCCoCr. It has very low sensitivity, presumably because the Co binder
in the carbide coating prevents field penetration.
Coating problems NOT caused by, or during, the grinding process are
detectable via visual inspection using a 10X loupe.
Fluorescent Penetrant Inspection
FPI is not to be used on as-sprayed surfaces
The inherently rough as-sprayed surface finish masks relevant
indications
The inherently rough as-sprayed surface finish traps the FPI
fluid making it difficult to rinse off
Some common FPI indications (Figure 5-3):
Pull-outs Carbide particles or small sections of coating
pulled out of surface during grinding not acceptable.
Porosity Excessive penetrant retention in pores not
acceptable.
Grind marks, spiraling and chatter Grinding marks within
surface finish spec acceptable. Grinding marks beyond
surface finish spec not acceptable.
In-service damage Acceptability depends upon whether it
can be polished out.
Page 27
Page 28
Page 29
Figure 5-4.
standard.
Page 30
5.4.1. Repair
Warning: HVOF
cannot be repaired.
Strip and recoat.
Page 31
6. ESOH
Warning: Breathing
of WC-Co powder
and dust should be
avoided. Use proper
dust masks when
handling powder or
grinding coatings.
Data on possible production of Cr6+ during HVOF spray of Crcontaining powders such as WC-CoCr and Cr3C2-NiCr is limited, but
HVOF is not believed to produce Cr6+ and there is no data showing
any entrainment of Cr6+ into the sprayed coating. However, there are
known ESOH issues associated with Co and with WC-Co 6 . The
following precautions should be followed when spraying or grinding
HVOF coatings:
Co has known ESOH issues, and Co in combination with WC
can trigger hard metal disease among workers exposed to
the powder.
Always wear a NIOSH-approved mask consistent with the
powder size when handling WC-Co and WC-CoCr powder or
grinding carbide coatings. This includes within spray booths,
when handling powders and powder feeders, when grinding,
and when handling bag house or other filters.
Maintain good housekeeping around areas where powder is
loaded, sprayed or ground.
Some powders contain Ni and should not be handled by
personnel known to be sensitive to Ni.
Note: The California Air Resources Board (CARB) has promulgated
rules for control of Cr6+ emissions from thermal spray processes
including HVOF 7 , citing emission rates that do not appear to be based
on actual measurements for HVOF systems in normal production
operation.
Page 32
7. Performance
7.1.Properties Summary
Table 7-1. Summary of HVOF performance.
Test
Capabilities
Limitations
Applications tested
Rig tests
Flight tests
P-3 landing gear and bomb bay door actuators, EA6B landing gear, Boeing 737 commercial landing gear
Fatigue
Cracking, spalling
Impact
Wear
Corrosion
Embrittlement
Fluid compatibility
Warning: The
coating deposition
parameters must
be optimized for
the application.
Warning: HVOF
coatings can crack
and spall at high
stress.
1. Coating integrity (cracking, spalling) at high load The strainto-failure of HVOF coatings is about 0.7% (about 180ksi stress
for high strength steels). Above this HVOF coatings on
landing gear and similar cylindrical parts that fatigue in
bending will develop a fine circumferential crack pattern. This
does not lead to failure or corrosion, but can lead to spalling at
long times or at high stresses. Spalling does not occur for
0.003 thick coatings below yield stress (230 ksi), but thicker
coatings spall at lower stress.
2. Carbide coatings develop circumferential cracks over
extended service, usually on tensile areas of hydraulics and
journals. Cracked coatings should be replaced on overhaul,
but have not been identified as an issue.
3. Carbides coatings are brittle HVOF carbide coatings are
more brittle than hard chrome and sharp edges must be
avoided. Coating runout is essential and grinding must be
done under a high level of control.
Page 35
REFERENCES
1
For a detailed summary of HVOF methods and data see Use of Thermal
Spray as an Aerospace Chrome Plating Alternative, K. Legg and J. Sauer
(Oct 2000) http://www.hazmatalternatives.com/DoD_reports_Cr_Alts.htm .
J-G.
Legoux,
HCAT
Program
Review,
January
2006.
http://www.materialoptions.com/w2g/cgi/kmcgi.exe?O=REV0000000NP3&V=
44/Legoux%20Water%20Jet%20Stripping%20and%20Potential%20Surface
%20Pre_V1.PDF
6
http://www.arb.ca.gov/regact/thermspr/fro1.pdf
Page 36