Zero fatigue knockdown of HVOF WC-Co-Cr coated specimens was not achieved, but considerable improvement was gained; Interaction of parameters and their affects on coating properties can be leveraged on other coatings and HVOF equipment; Failure analysis of fatigue specimens gave valuable insight in determining how the HVOF process can be further refined; Failure initiation was subsurface in each specimen; Large inclusions were found at the majority of failure initiation sites; Compressive stress of shot peen layer was altered; Optimized parameters in the Boeing thermal spray specification will give a more consistent coating; Though zero fatigue knockdown was not achieved, gaining an improved CFF will all for parts to be downsized; Therefore, the goal of weight reduction can be achieved.
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