• Korean Journal of Metals and Materials
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• v.47 no.5
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• pp.290-296
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• 2009

We report on the effects of mixing of powders with various particle sizes on fracture toughness and wear resistance of thermally sprayed WC-10Co-4Cr coating layers fabricated by HVOF (high-velocity oxygen fuel) process. The size and the mixing ratio of powders were changed in order to get high fracture toughness and wear resistance. The mixing of small amount of coarse powders with fine powders resulted in the highest fracture toughness and wear resistance due to the lowest porosity in coating layers.

• Transactions of the Korean Society of Automotive Engineers
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• v.24 no.3
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• pp.285-293
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• 2016

The high velocity oxygen fuel(HVOF) thermal spray is a kind of surface modification techniques to produce the sprayed coating layer. This process is to form the coating layer after spraying the powder to molten or semi-molten state by the ultra-high speed at the high-temperature heat source and conflicting with a substrate. The efficiency of thermal spraying is dropped, however, because the semi-molten powder in a spray process become a factor that degrades the mechanical property by the formed pore within the coating layer. Therefore, it is necessary to melt completely the thermal spray powder in order to produce the coating layer with an optimal adhesive force. In this study, to improve the wear resistance, corrosion resistance and heat resistance, the plungers of high-speed and ultra-high pressure reciprocating hydraulic pumps used in ironworks are manufactured with STS $420J_2$ and are coated by the powders of WC-Co-Cr and WC-Cr-Ni including the WC of high hardness using a HVOF thermal sprayer developed in this laboratory. These are called by the surface-modified plungers. The surface roughness, hardness, and surface and cross-sectional microstructure of these two surface-modified and conventional ceramic plungers are measured and compared before operation with after operation for 100 days. It is found that the values of centerline average surface roughness and maximum height for conventional ceramic plunger are 9.5 to 10.8 and 5.2 to 5.7 times higher than those of surface-modified ones coated by WC-Co-Cr and WC-Cr-Ni because the fine tops and bottoms on surface roughness curve of conventional ceramic plunger are approximately 100 times higher than those of surface-modified ones. In addition, the pores and scratches in the surface microstructure are considerably formed in the order of conventional ceramic, WC-Cr-Ni and WC-Co-Cr surface-modified plungers. The greater the WC content of high hardness powder is less the change in the plunger surface.

• Journal of the Korean Ceramic Society
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• v.53 no.6
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• pp.628-634
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• 2016

The 8 wt% yttria($Y_2O_3$) stabilized zirconia ($ZrO_2$), 8YSZ, a typical thermal barrier coating (TBC) for turbine systems, was fabricated under different starting powder conditions and coating parameters by atmospheric plasma spray (APS) coating process. Four different starting powders were prepared by conventional spray dry method with different additive and process parameter conditions. As a result, large- and small-size spherical-type particles and Donut-type particles were obtained. Dense structure of 8YSZ coating was produced when small size spherical-type or Donut-type particles were used. On the other hand, 8YSZ coating with a porous structure was formed from large-size spherical-type particles. Furthermore, a segmented coating structure with vertical cracks was observed after post heat treatment on the surface of dense structured coating by argon plasma flame at an appropriate gun distance and power condition.

• Korean Journal of Materials Research
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• v.11 no.9
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• pp.763-768
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• 2001

Molybdenum-based thermal spray powder is widely used for coating the moving parts of the internal combustion engines due to its excellent wear resistance. A composite powder of the $Mo_{40}(Al_{1-x}Si_x)_{60}$ system was synthesized using the SHS method. The synthesized bulk was pulverized and specially treated to produce thermal spray powder. It was found that the synthesis reaction consisted of two-steps: the formation of $Al_8/Mo_3$ and the formation of Mo(Al,Si)$_2$. Both the temperature and the rate of the SHS reaction linearly increased with the increase of the value of x in $Mo_{40}(Al_{1-x}Si_x)_{60}$, The temperature and the rate of the reaction were also affected by the compacting density of the specimens, exhibiting the maximum valves at 62% and 60%, respectively. Since spherical shape is advantageous to the thermal spraying process, shape-control of the powder was attempted with PVA as a binding additive, resulting in the successful production of almost perfectly spherical powder of 80 $\mu\textrm{m}$ Ø$(d_{50})$ mean particle size.

• Journal of Powder Materials
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• v.12 no.2 s.49
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• pp.136-145
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• 2005

Graphite-Ni composite powders were synthesized by mechanical alloying(MA) and spray drying(SD). Fabricated powders as well as commercial graphite-Ni powders were thermally sprayed on mild steel substrates using high velocity oxygen fuel (HVOF) thermal spray process and flame thermal spray process. The effects of several process parameters on related properties in thermally sprayed coatings have been investigated and correlated with microstructures in this study. The results indicated that the desired properties can be obtained when commercial powders were applied using HVOF process, while coating properties in case of MA powder application were inferior to those in HVOF process in so far. However, it is suggested that property enhancement can be obtained if the fraction of hexagonal graphite phase can be increased in mechanically alloyed powders.

• Proceedings of the KWS Conference
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• 2010.05a
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• pp.32-38
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• 2010

Hybrid material(ceramic+metal) processes were developed for micro filter using ceramics coating at metal filter surface by thermal spray method, micro hole drilling at ceramic coated filter surface by femtosecond laser, and fiber laser direct welding of ceramic and metal (SUS304, SM45C) by capillary effect. Thermal spray process was used for ceramic powders and metal filters. The used ceramic powders were $Al_2O_3+40TiO_2$(Metco 131VF) powder of maximum particle size $5{\mu}m$ and ${Al_2O_3}99+$(Metco 54NS) power of maximum particle size 45m. Ceramic coated filters using thermal spray method had a great influence on powder material, particle size and coating thickness but had a fine performance as a micro filter. CW fiber laser was used to drill the top ceramic layer and melt the bottom metal layer for joining applications.

• Proceedings of the Korean Powder Metallurgy Institute Conference
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• 2003.10a
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• pp.97-98
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• 2003

• Journal of the Korean institute of surface engineering
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• v.40 no.4
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• pp.170-174
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• 2007

High Velocity Oxygen Fuel (HVOF) thermal spray coating of nano size WC-Co powder (nWC-Co) has been studied as one of the most promising candidate for the possible replacement of the traditional hard plating in some area which causes environmental and health problems. nWC-Co powder was coated on Inconel 718 substrates by HVOF technique. The optimal coating process obtained from the best surface properties such as hardness and porosity is the process of oxygen flow rate (FR) 38 FMR, hydrogen FR 57 FMR and feed rate 35 g/min at spray distance 6 inch for both surface temperature $25^{\circ}C\;and\;500^{\circ}C$. In coating process a small portion of hard WC decomposes to less hard $W_2C$, W and C at the temperature higher than its decomposition temperature $1,250^{\circ}C$ resulting in hardness decrease and porosity increase. Friction coefficient increases with increasing coating surface temperature from 0.55-0.64 at $25^{\circ}C$ to 0.65-0.76 at $500^{\circ}C$ due to the increase of adhesion between coating and counter sliding surface. Hardness of nWC-Co is higher or comparable to those of other hard coatings, such as $Al_2O_3,\;Cr,\;Cr_2O_3$ and HVOF Tribaloy 400 (T400). This shows that nWC-Co is recommendable for durability improvement coating on machine components such as high speed spindle.

• Korean Journal of Materials Research
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• v.12 no.10
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• pp.809-813
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• 2002

Commercial nano crystalline $TiO_2$ powders were used to characterize photocatalyst, using thermal spray coating technique. The microstructure of coating layers were examined by SEM, FE-SEM and TEM. Also the cross sectional areas of TiO$_2$ coating layers were observed by SEM. The phases were analyzed by X-ray diffraction methed. Surface roughness and hardness were measured. It was found that phase transformation from anatase to rutile occurred, and the melted splats are all rutile, and unmeted nano particles were anatase. These unmelted anatase phase may enhance te play a role of photocatalyst.

• Journal of the Korean institute of surface engineering
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• v.39 no.4
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• pp.179-189
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• 2006

High velocity oxygen fuel(HVOF) thermal spray coating of WC-Co powder is one of the most promising candidate for the replacement of the traditional hard chrome plating and ceramics coating because of the environmental problem of the very toxic $Cr^{6+}$ known as carcinogen and the brittleness of ceramics coating. WC-Co micron and nano powder were coated by HVOF thermal spraying method for the study of durability improvement of the high speed spindle. Coatings were planned by Taguchi program for the four spray parameters of spray distance, flow rates of hydrogen, oxygen and powder feed rate. Optimal coating process was obtained by the studies of coating properties such as porosity, surface roughness, micro hardness, and micro structure. WC-Co micron and nano powder were coated on the Inconel 718 substrate by the optimal coating process obtained in this study. The wear behaviors were studied by the sliding wear tester at room temperature and at an elevated temperature of $500^{\circ}C$ for the application to high speed spindle. Sliding wear test was carried out for four most promising hard coatings of chrome coating, ceramics coatings such as $A1_2O_3,\;Cr_2O_3$ and HVOF Co-alloy T800 for the comparison of their wear behaviors. HVOF WC-Co coating was better than other coatings showing highest micro hardness of 1400 Hv and comparable friction coefficients with others. HVOF WC-Co coating is a strong candidate for the replacement of the traditional hard chrome plating for the high speed spindle.