Flame spray technology is basic member of the thermal spray coating family. Higher cost-effective coatings can be produced at higher speeds with new flame spray equipments which developed in recent years. The Flexicord flame spray method developed in this direction offers many advantages. A wide variety of ceramic coatings can be deposited on metallic surfaces with this spray methods in the face of wear-induced problems. In this study, solid particle erosion rates and wear behaviors of different oxide (Al2O3, MgOZr2O3, Al2O3-MgO based coatings have been studied comparatively with respect to ASTM G76 standard. Spinel based coatings between the oxide based coatings exhibited superior wear resistance and significantly lower mass loss than the others. Due to the fragile nature of the ceramic coatings, the erosive wear rate is increased by crack growth formation related with the porosity of coating. Due to the accelerated solid particle impacting at high impact angles, wear rate is highest.

Variety thermal spray coatings are used to improve wear performance and life span of part in many industrial applications. The solid particle erosive wear mechanisms of the lamellar structured thermal spraying coatings are not still clearly understood. In this study, the wear behavior of different oxide based coatings produced using the flexicord flame spray gun developed in recent years has been investigated on many aspects. The wear rates of flame spray coatings in different composition (alumina, chromia, spinel, zirconate) and thicknesses were compared. In order to determine the effect of heat treatment on the wear performance, heat treatment was performed at 700 • C for 60 h and the wear rate of the coatings were measured. As a result, coating quality, thickness and composition have been found to play an important role in erosive wear behavior. It has been observed that the wear rates vary depending on the different angle of impact. Discontinuities in the coating structure, splat thickness and porosity seem to affect the wear resistance of the coating. As a result of the work, it is understood that oxide based flame spray coatings increase the wear resistance of the metallic part. Among these coatings, the best wear performance has been demonstrated by chromium oxide coatings.