International Journal For Technological Research In Engineering
Volume 3, Issue 2, October-2015
A REVIEW OF HVOF THERMAL SPRAY COATING TECHNIQUE
ON METAL PLATE
Gaurav Gupta1, Gaurav Acharya2, Antariksha Verma3
1
M.Tech Student in Manufacturing and Industrial Ngg.
2,3
Asst. Professor Manufactring and Industrial Engg
Suresh Gyan Vihar University Jaipur (Rajasthan).
Abstract: Thermal spray coating is used to synthesises the
surface of the metal bodies. In today’s progressive world
where modification of the substrate material are carried
very much, there is much need of these new technology of
coating. In the field of the surface modification thermal
spray coating, electroplating, powder metallurgy and other
metallurgical process are used very rapidly. In this review
paper we have represented the overview of all different
types of thermal spray coating and the benefits of the high
velocity oxy fuel coating. Literature review is presented and
on behalf of that an experiment was conducted to show the
effect of coating on mild steel plate.
Keywords: Thermal spray, powder metallurgy, mild steel
plate, WC-10Co-4Cr, HVOF, wire spray.
I. INTRODUCTION
A metal plate with having high strength is much needed for
the industrial purpose. The life durability to withstand for the
longer time so that it would be economical for the industries
and needs less maintenance required. For this in this
progressive world different new modification technology are
developed and new research are going on so that a better
result could be obtained after modification. For the surface
modification in industries lots of technology are used for
different purposes so that it would be economical for that
industries. There are so many different process such as
thermal spray coating, electroplating, electro chemical
deposition technique, thermal barrier coating, powder
metallurgy etc. Now we will summarize all these process in
short so that we can understand the uses and its function. In
electroplating the coating of very thin membrane of metal
powder is coating on the aluminium or brass metal so that it
would be rust free and having bright shining. In
electroplating there are two nodes one is cathode and other is
anode. The base metal is anode and the material from the
cathode is moved to the anode. But electroplating is slow
process as thermal spray coating process. After that the next
advancement is of electro-chemical deposition process. In
electro chemical process, the metal deposition is carried out
in the closed chamber an electrolyte is used as medium for
the reaction and anode and cathode are used and by reaction
the metal deposition is carried out, but it is slow process so it
cannot be used for large industrial process. After that powder
metallurgy is one of the best methods for the modification of
the substrate metal plate. In powder metallurgy the metal is
poured in the powder form in the powder feeder and with
having uniform thickness and less defects the casted metal is
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ISSN (Online): 2347 - 4718
obtained. Now the most important one is thermal spray
coating that have advanced technology in the industrial
surface modification process. In thermal spray coating the
molten metal is heated in the combustion chamber and
sprayed through the spray gun on the metal or alloy plate for
coating. It is used for the protection of the new parts from the
weir and fatigue. In this review paper we will focus on the
thermal spray coating technique and its advancements in the
recent years. Thermal spray coating can be done by various
methods of coating such as detonation gun spray, high
velocity oxy flame spray, wire flame spray, plasma spray, arc
spray etc. Thermal spray coating was firstly introduced by
the Swiss engineer Max Ulrich Schoop (1870-1956)
He found that when molten motel get heated in the hot
chamber then they collide and can make sticky layer on the
plate as coating. The big advantage of the thermal spray
coating is that it can be used on the repair site as compared to
other deposition techniques. The coating thickness that can
be obtained could be of 10 mm.
II. PRINCIPLE
The most basic principle of the thermal spray coating is that
the thermal energy that is generated is used for the heating
and melting of the metal powder in the combustion chamber
through feedstock. After that the spray gun is used for the
flow or spray of the molten metal particle with very high
speed. The molten metal gets kinetic energy from the
combustion of the gases such as acetylene and oxygen or
LPG gas to accelerate the powder particles. Thermal spray
coating has different types of layers such as lamellar
structure. Lamellar structure is a layer like a sandwich
structure. The porosity is very low in the thermal spray
coating process as compared to other deposition process.
III. THERMAL SPRAY TECHNIQUES
There are so many different types of thermal spray
techniques that are being used in the industries. They are as
follows:-
 Powder or wire flame spray.
 Detonation gun spray.
 High velocity oxy fuel.
 Plasma spray technique.
 Arc spray.
 Laser spray.
 Cold spray method.
 Flames spray method.
Powder or wire flame spray:- It is low energy thermal spray
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International Journal For Technological Research In Engineering
Volume 3, Issue 2, October-2015
technique. Coating materials that is used for the deposition is
in the wire form. The spraying cost is rather low as compared
to other process.
Fig.1. Flame Spray.
Detonation Gun Spray:- In this system the water cooled
barrel is provided, the fuel and gas mixture is provided with
the powder as charge. The detonation in the barrel causes the
movement of the powder particle to accelerate.
Fig.2. Detonation Gun Spray.
High Velocity Oxy Fuel: - In this system the velocity of the
fuel/ gas mixture is very high. The high velocity spray
provides very dense coating and very low level of porosity i.e
> 1 %. It have extended nozzle so that the high velocity can
be created.
Fig.3. HVOF spray.
Plasma Spray Coating:- In plasma spray coating an anode
and thoriated tungsten as cathode is used for the formation of
the plasma. The electric arc discharge heats up the working
gas. The working gases that are used are mainly Ar or a
mixture of Ar + H2. The temperature is more high like 13500
K and high speed is used. The thickness of coating could be
of 50- 500 µm.
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ISSN (Online): 2347 - 4718
IV. LITERATURE REVIEW
In the field of thermal spray coating so many research and
projects are going on in the world. Thermal spray coating is a
new technology in the metallurgical advancement.
According to Kumars & Houlday thermal spray coating was
used for continues casting slab for the enrichment of strength
of base metal by using chromium coating. MD. ASHIF et al
In this study, the effect of micron-sized titanium and
aluminium addition on the micro structural, mechanical and
work-hardening behaviour of pure Mg is investigated.
Tensile results indicate that the direct addition of micron-
sized 10wt.% titanium particulates to pure Mg. GARTNER.
F et al Thermal sprayed coating done over low carbon steel
components, for protecting against corrosion and wear. This
paper stated for the verifying the efficiency of the high
velocity combustion wire spray process for X46Cr13
stainless steel. For the analysis of the coating microstructure
and mechanical properties were conducted. DOSTA SERGA
et al To obtain different coating properties on TiC- stainless
steel or NiTi matrix by plasma and HVOF spray process
used. The particle size was taken as 21 and 62 µm for
thermal spray coatings. After that author performed XRD
and SEM-EDS to obtain the surface and cross section. Some
other testing were also performed such as coating adhesion,
wear resistance and corrosion.SUHONEN TOMMI et al the
author reviewed the process optimization, characterization of
the HVOF techniques, methods and tools for the coating
process on the substrate materials. SINGH S.C et al By using
detonation gun spray technique the modification technique
have been used to improve the wear resistance of EN8 steel
base metal. In this, the alloy powder WC-10Co-4Cr AND
Al2O3-13TiO2 have been used. SANTANA.Y.Y et al In this
paper the author investigated the mechanical and
microstructure properties of two WC materials. Author
performed two testing for the mechanical properties, they are
hardness and elastic modulus. For the microstructure
properties XRD and SEM have been performed to view the
coating structure. Houdokava saraka et al the power loss in
the engine could be reduced by using thermal spray a coating
which was caused by friction between piston, piston rings
and cylinder. For this the author performed HVOF coating
process. Coating powder were WC- based and CrC- based.
NI LIYONG et al the coating of NiCrAlY was prepared by
HVOF coating process i.e. a thermal spray coating. The
coating was performed on the nickel based superalloy.
WANG BO et al By HVOF WC-10Co-4Cr was coated on
the substrate metal AISI 1045 steel. The optical microscopy,
SEM, XRD, EDS, DSC, HRTEM were analyzed. It was
found that coating with having 0.86 % porosity have dense
coating and good thermo stability. The result showed that
corrosion rate was very low as compared to earlier. PALKA
PAWEL et al In this paper, the author investigated the
micro-hardness, microstructure, phase consistent of thermal
spray coating of WC, CrC, NiCrSiB coating were analyzed.
Optical microscopy, SEM, TEM, XRD have been performed
for the microstructure and phase consistent.
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International Journal For Technological Research In Engineering
Volume 3, Issue 2, October-2015
V. EXPERIMENATAL WORKS
Fig.4. flow diagram of process.
VI. RECENT ADVANCEMENT IN HVOF COATING
In the field of HVOF coating lots of research is going on
because it have great advantage over other thermal spray
coating process. According to the literature survey we have
found that HVOF coating causes uniform thickness of
coating and high hardness after coating on the metal or alloy
plate. For this we have undergoes through an experiment for
the study of different parameters effect on the coating.
According to the S.G.junior the HVOF coating was applied
on the AISIS 4340 steel plate for the aeronautical purpose.
The plate was coated with the hard chromium. The main aim
of this study was for the comparision of the coating by
HVOF and other process. After that it was found that HVOF
provides high hardness and less porosity percentage.
According to z. Chungen he researched on the effects of the
surface modification on thermal cycling life time barrier
coating with HVOF NiCrAlY bond coat. In which he have
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studied about the experiment on other surface modification
method such as grit blasting, chot peening etc. But it was
found that bond coat have high strength and high hardness
asa compared to other. According to Cinca Nuria she
explained about the wear and corrosion of metal matrix TiC
coating. She explained about the advancement about the
Different spraying technologies (plasma and High Velocity
Oxi-Fuel) have been use to obtain TiC - stainless steel or
NiTi matrix coatings. The starting feedstock powders have
been obtained by SHS technology. After crushing and
sieving, the fraction of particles between 20 and 63 μm, have
been selected for thermal spray. The obtained coatings have
been characterized by XRD and SEM-EDS to observe the
surface and cross section. The coatings adhesion, wear (ball-
on-disk and rubber wheel tests) and electrochemical
corrosion test have been carried out. L.S.F Mouih stated
about the evaluation of the WC-10Ni thermal spray coating
with shot peening on fatigue strength of AISI 4340 steel
plate. The aim of present study is to compare the influence of
WC-10 Ni coating applied by HVOF on the fatigue strength
of AISI 4340 steel, with and without shot peening. S-N
curves were obtained in axial fatigue tests for material base,
and tungsten carbide coated specimens. Wang Quin stated
that microstructure and properties of HVOF spraying of WC-
10Co-4Cr coatings. Three WC-10Co-4Cr coatings were
deposited with various spraying parameters (6 and 6.5 GPH
kerosene flux, 1850 and 1950 SCFH oxygen flux, and 330
and 380mm spray distance) by using Parxair JP-8000 HVOF
thermal spray system. The coating properties such as
hardness, crystalline phase, fracture toughness, thickness per
pass and abrasive wear resistance have been investigated. It
was found that fatigue strength was found better as
comparison to other methods. Ragupathy .A setup an
empirical relationship between to predict hardness of WC-
10Co-4Cr HVOF sprays coatings. In which he explained
about the result on the hardness of coatings, for establishing
the relation the author used the four parameters as oxygen
flow rate, powder feed rate, LPG flow rate, standoff distance
etc.
VII. CONCLUSON
After all these studies and literature review it was concluded
that thermal spray coating is one of the most important
technique of the surface modification method. In thermal
spary coating HVOF coating is best suited over all other
thermal spray coating such as detonation gun spray, plasma
spray, arc spray, flame spray etc. By using HVOF spray
technique high hardness upto 1500 HV0.3 can be obtained.
The volume fraction % porosity level can be achieved upto 1
%. The SEM and microstructure results showed that coating
done by this process have uniform coating thickness and
have continuous layer of coating. According to many
researchers research it was confirmed that HVOF thermal
spray coating is best method and have more advantages over
the high strength, hardness, porosity, wear and corrosion as
compared to other process.
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International Journal For Technological Research In Engineering
Volume 3, Issue 2, October-2015 ISSN (Online): 2347 - 4718

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