Influence of HVOF Setting Parameters on Nickel-Based Alloy Powder (Diamalloy 1005) Coating Properties

摘要

To protect the metallic surface from the high temperature and/or highly corrosive environment, HVOF coating of the substrate material is considered. The coating not only protects the surface, but it also extends the life of the base metal surface. This improves equipment operational availability and reduces cost. However, many parameters can affect metallic coating properties, especially unmelted particles and oxidation level. Setting parameters such as powder feed rate and spray distance are of prime importance. The aim of this work was focused on the influence of these parameters on nickel-based alloy powder (Diamalloy-1005) coatings characteristics. All of these parameters were critical factors in coating porosity and coating corrosion resistance. Microstructure investigations as well as oxide content measurements and microhardness were obtained to determine the coating quality. In addition, corrosion tests were carried out in an attempt to find the best coating properties that would resist the challenging environmental conditions that equipment faces, especially in the Gulf area. It appeared that an increase in the powder feed rate increased the porosity and decreased coating hardness. Also, an increase in the spray distance allowed the particles to slow down and lose their kinetic energy, allowing them to oxidize, leading to increased corrosion.