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The concept of Ôprocess mapsÕ has been utilized to study the fundamentals of process-structure-property relationships in high velocity oxygen fuel (HVOF) sprayed coatings. Ni-20%Cr was chosen as a representative material for metallic alloys. In this paper, integrated experiments including diagnostic studies, splat collection, coating deposition, and property characterization were carried out in an effort to investigate the effects of fuel gas chemistry (fuel/oxygen ratio), total gas flow, and energy input on particle states: particle temperature (T) and velocity (V), coating formation dynamics, and properties. Coatings were deposited on an in situ curvature sensor to study residual stress evolution. The results were reconciled within the framework of process maps linking torch parameters with particle states (1st order map) and relating particle state with deposit properties (2nd order map). A strong influence of particle velocity on induced compressive stresses through peening effect is discussed. The complete tracking of the coating buildup history including particle state, residual stress evolution and deposition temperature, in addition to single splat analysis, allows the interpretation of resultant coating microstructures and properties and enables coating design with desired properties.

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