Process mapping is an ideal method for tracking coatingcharacteristics in the thermal spray process. With the increasedutilization of in-flight particle diagnostic tools in recent yearsit is now possible to quickly and effectively characterize inflightpowder particle properties. With industries' increasingunderstanding of the relationship of these properties andcoating characteristics, it is now possible to rapidly understandthe implications of in-process changes with respect to coatingperformance.This paper is an exploratory exercise that describes theutilization of process mapping [1] of in-flight particle velocityand temperature characteristics to optimize tungsten carbide(WC) coatings sprayed with a High Velocity Plasma torch(HVP).Key performance factors of WC coatings include highinherent hardness, low porosity and neutral to compressivestress conditions. The combination of these factors allcontribute to the coatings' overall success in it's intendedapplication and elude to its toughness, wear resistance,corrosion resistance and general ability to protect the requiredcomponents. Presently, the High Velocity Oxygen Fuel(HVOF) and High Velocity Liquid Fuel (HVLF) combustionprocesses are the favored method of applying dependable andcommercially viable WC coatings that meet all of thesecriteria.
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