Coatings of Carbide-Metal Systems (Cr3C2-NiCr and WC-Co-Cr) Deposited by High-Velocity Atmospheric Plasma Spraying from Specially Modified Fine-Grained Powders

Abstract

In this article, the author poses and responds to a provocative question that has practically ceased to be asked in the field of thermal spraying of carbide coatings: Is the current worldwide trend of using only unmelted metal particles to form coatings (HVOF, HVAF and cold spray methods) correct, and is the deposition of completely melted powders (plasma spraying methods) really outdated? The results of high-speed plasma deposition of new carbide powders allowed the author to prove that only coatings from molten particles can solve the main problem of such coatings, namely the problem of permeability along the grain boundaries. Through the use of modern Axial III plasma torches combined with optimized fine-grained powders, it has been possible to create Cr3C2-NiCr as well as WC-Co-Cr gas-tight layers.

SPH simulation of YSZ and stainless-steel droplet impact for thermal spray process

“…However, thermal spray technology was not widely utilized in the early stage due to low reliability and less sophistication because the early thermal spray process could not handle corrosion issues. It began to be applied in industry in recognition of its higher efficiency in surface restoration and performance enhancement in terms of improved surface properties and longer component lifetime in the early 1990s [32][33][34][35].…”