Manufacturing of nickel based cermet coatings by the HVOF process

Advanced particle diagnostic technology has been applied to establish process parameters to deposit high quality nickel based carbide cermet coatings for marine hydraulic applications. The cermet coatings are produced via the kerosene fuelled high velocity oxygen fuel (HVOF) spray process, which uses a hypersonic flame jet to melt and accelerate feedstock particles onto the component surfaces. The traditional 'trial and error' procedure is not technically robust, as well as being costly and time consuming. Instead, a superior method is implemented in the current study that performs real time monitoring of the process parameters associated with the HVOF flame jets. Subsequently, coatings can be produced with the knowledge of the inflight particle size, temperature and velocity profiles. The analytical results allow identification of suitable coating process parameters, which translate to coatings of lower porosity and enhanced mechanical performance.