A Study on the Properties, Friction, Wear and Adhesion of HVOF Thermal Spray Coating of Micron Size Co-Alloy Powder

High velocity oxygen fuel (HVOF) thermal spray coating of micron size (mu) T800 powder has been studied for the durability improvement of sliding machine components. The optimal coating process (OCP), surface properties, friction, wear behavior and adhesion of HVOF T800 coating have been investigated. The temperature dependence of friction coefficient and wear behavior have been studied at 25 degrees C and at an elevated temperature 538 degrees C (1,000 degrees F) for the study of the temperature effects on FC and wear behaviors of the coating and for the application on high speed air bearing spindle which operates with no lubricants. The OCP was determined from the best surface properties of the 16 OCP searching coatings designed by the Taguchi experimental program of four spray parameters with three levels: a hydrogen flow rate (FR) of 38-42 FMR (1 FMR=12scfh=9.44x10(-5) m/s), oxygen FR of 65-70 FMR and feed rate of 30 g/min, and a spray distance of 5 inch. Hardness, roughness and porosity observed from the 16 coatings were 560-640 Hv (5488-6272 MPa), 2.2-3.0 mu m and 0.01-0.04% respectively. Friction coefficient (FC) decreased from 5.5-7.0 to 4.8-6.0 with increasing the sliding surface temperature from 25 degrees C to 538 degrees C because of the higher lubrication effect of Co oxide debris at the higher temperature. Wear trace of the coating and counter sliding SUS 304 surface decreased to more than a half with increasing the sliding surface temperature from 25 degrees C to 538 degrees C. Tensile bond strength (TBS) and tensile fracture location (TFL) of Ti64 / T800 were 8,770 psi (60.5 MPa) and near the middle of the coating respectively. Bond coat NiCr did not influence on the TBS of the coating. The adhesion between Ti64 substrate and T800 coating (Ti64/T800) was stronger than the cohesion strength 8,770 psi (60.5 MPa) of T800 coating. These showed that Ti64/T800 coating was recommendable for durability improvement coating on high speed spindle of Ti64.