The Effect of HVOF Particle-Substrate Interactions on Local Variations in the Coating Microstructure and the Corrosion Resistance

Splashing and redeposition of droplets occur during thermal spray processing, which affects the coating porosity and morphology. Therefore, this phenomenon is important from a practical point of view such as corrosion. Particle interaction with substrate is a function of the particle velocity, viscosity, temperature, as well as the substrate temperature, chemistry, roughness, and geometry. In the present study, the splashing phenomenon was studied on CrC-NiCr and stainless steel materials deposited using the high velocity oxygen fuel process. The effect of particle splashing on the coating microstructure was investigated with respect to the corrosion properties. Particle behavior during impact was explained based on in-flight particle velocity and temperature measurements. It was found that the conditions that favor particle splashing promote occurrence of localized porosity. The localized porosity was a strong function of the substrate curvature and originated from the substrate asperities.