• 한국자동차공학회논문집
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• 제24권3호
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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.

• 한국재료학회지
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• 제29권1호
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• pp.52-58
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• 2019

The microstructure, hardness, and wear behaviors of a High Velocity Oxygen Fuel(HVOF) sprayed WC-CoFe coating are comparatively investigated before and after laser heat treatments of the coating surface. During the spraying, the binder metal is melted and a small portion of WC is decomposed to $W_2C$. A porous coating is formed by evolution of carbon oxide gases formed by the reaction of the free carbon and the sprayed oxygen gas. The laser heat treatment eliminates the porosity and provides a more densified microstructure. After laser heat treatment, the porosity in the coating layer decreases from 1.7 % to 1.2 and the coating thickness decreases from $150{\mu}m$ to $100{\mu}m$. The surface hardness increases from 1440 Hv to 1117 Hv. In the wear test, the friction coefficient of coating decreases from 0.45 to 0.32 and the wear resistance is improved by the laser heat treatment. The improvement is likely due to the formation of oxide tribofilms.

• 대한금속재료학회지
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• 제46권6호
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• pp.351-356
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• 2008

Thermally sprayed tungsten carbide-based powder coatings are being widely used for a variety of wear resistance applications. The coating deposited by high velocity processes such as high velocity oxy-fuel (HVOF) thermal spraying is known to provide improved wear resistant property. In this study, optimal coating process (OCP) is obtained by the study of coating properties such as surface hardness, porosity, surface roughness and microstructure of 9 coatings prepared by Taguchi program for 3 levels of four spray parameters. The Friction and wear behaviors of HVOF WC-CoCr coating prepared by OCP, electrolytic hard chrome (EHC) plating and Inconel718 (In718) are investigated by reciprocating sliding wear test at $25^{\circ}C$, $450^{\circ}C$. Friction coefficients (FC) of all of the 3 samples are decreased as increasing sliding surface temperature from $25^{\circ}C$ to $450^{\circ}C$. FC of WC-CoCr decreases as increasing the surface temperature from $0.33{\pm}0.02$ at $25^{\circ}C$ to $0.26{\pm}0.02$ at $450^{\circ}C$, showing the lowest FC among the 3 samples. Wear trace (WT) and wear depth (WD) of WC-CoCr are smaller than those of EHC and In718 both at $25^{\circ}C$ and $450^{\circ}C$. These show that WC-CoCr is highly recommendable for protective coating on In718 and other metal components.

• 한국표면공학회지
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• 제45권6호
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• pp.264-271
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• 2012

Due to the good corrosion resistance and machinability, copper alloy is commonly employed for shipbuilding, hydroelectric power and tidal power industries. The Cu alloy, however, has poor durability, and the seawater application at fast flow condition becomes vulnerable to cavitation damage leading to economic loss and risking safety. The HVOF(High Velocity Oxygen Fuel) thermal spray coating with WC-10Co4Cr were therefore introduced as a replacement for chromium or ceramic to minimize the cavitation damage and secure durablility under high-velocity and high-pressure fluid flow. Cavitation test was conducted in seawater at $15^{\circ}C$ and $25^{\circ}C$ with an amplitude of $30{\mu}m$ on HVOF WC-10Co4Cr coatings produced by thermal spray. The cavitation at $15^{\circ}C$ and $25^{\circ}C$ exposed the substrate in 12.5 hours and in 10 hours, respectively. Starting from 5 hours of cavitation, the coating layer continued to show damage by higher than 160% over time when the temperature of seawater was elevated from $15^{\circ}C$ to $25^{\circ}C$. Under cavitation environment, although WC-10Co4Cr has good wear resistance and durability, increase in temperature may accelerate the damage rate of the coating layer mainly due to cavitation damage.

• 한국표면공학회:학술대회논문집
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• 한국표면공학회 2008년도 추계학술대회 초록집
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• pp.153-154
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• 2008

High velocity oxy-fuel (HVOF) thermal spraying coating has been used widely throughout the last 60 years mainly in defense, aerospace, and power plants. Recently this coating technique is considered as a promising candidate for the replacement of the traditional electrolytic hard chrome plating (EHC) which pollutes the environment and causes lung cancer by toxic hexa-valent $Cr^{6+}$. In this study, two kinds of cermet coatings, WC-CoCr and WC-CrC-Ni, are formed by HVOF spraying. The wear properties of coatings are evaluated comparatively by reciprocating sliding wear tests at $25^{\circ}C$, $250^{\circ}C$ and $450^{\circ}C$ respectively. Wear rates show that WC-CoCr coatings have better sliding wear resistance than WC-CrC-Ni coatings regardless of temperature due to more, compact and homogeneously distributed WC particles, less metal content, Co, Cr rich metallic bindermatrix with higher fracture strength and better adhesive strength with WC particles.

• 한국산학기술학회논문지
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• 제21권6호
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• pp.204-211
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• 2020

경질 크롬 도금은 도금과정에서 유독성 물질인 Cr⁺⁶을 배출시키기 때문에 환경오염과 폐암을 유발하고 있어 최근 고속화염 용사법 (HVOF)을 이용한 코팅 방법이 대체 방법으로 각광받고 있다. 본 연구에서는 HVOF 방법을 이용하여 경질 크롬 도금 방법을 대체하기 위한 WC-CoCr과 WC-CrC-Ni 서멧 코팅을 제조하였으며, 제조된 코팅층의 물리적/화학적 특성인 미세경도, 기공도, 결정상 및 미세구조를 경도기, 광학현미경, X-선 회절 (XRD), 주사전자현미경(SEM) 및 EDS를 이용하여 분석하였다. 코팅층의 마모 및 마찰 거동 분석을 위해 왕복 슬라이딩 마모 테스트 방법을 이용하여 25 ℃, 250 ℃, 450 ℃의 온도에서 실시하였으며, 두 코팅층의 마모/마찰 특성을 비교 평가하여, 코팅층의 내마모 성능이 미세구조와 금속기지 결합제 간의 연관성이 있음을 확인하였다. 결과적으로 미세구조가 균일하고, 기공도가 낮을수록 내마모성이 향상되고, 금속기지 결합제가 많을수록 우수한 내마모성을 나타내는 것으로 확인되었다. 즉, 균일한 미세구조와 과량의 Co, Cr 금속기지 결합제, 낮은 기공도로 인해 온도와 테스트 온도와 관계없이 WC-CoCr 코팅이 WC-CrC-Ni 코팅에 비해 내마모성이 우수한 것으로 나타났다.

• 한국표면공학회:학술대회논문집
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• 한국표면공학회 2007년도 추계학술대회 논문집
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• pp.138-139
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• 2007

The microstructure and micro-hardness of high velocity oxygen fuel-sprayed (HVOF) WC-CoCr coatings are comparatively studied for both before and after laser heat-treatment (LT) of the coatings. The results indicate that compared to HVOF WC-CoCro coating, the laser treatment has eliminated the pores almost entirely providing a more homogeneous and densified microstructure. And the compact interface of the coating with substrate is achieved by laser treatment. The thickness of the coating has decreased from 300 ${\mu}m$ to 225 ${\mu}m$ As a result, the average porosity is five times higher in HVOF coating than in the coating by laser treatment. The laser treatment has produced a considerable increment in the hardness of the coating near surface whose average value increases from Hv0.2=1262.4 in the HVOF-sprayed coating to Hv0.2=1818.7 in the coatings treated with laser.

• 한국표면공학회:학술대회논문집
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• 한국표면공학회 2007년도 추계학술대회 논문집
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• pp.21-22
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• 2007

• 한국재료학회:학술대회논문집
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• 한국재료학회 1995년도 추계 학술발표 강연 및 논문개요집
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• pp.124-124
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• 1995

• 한국재료학회지
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• 제31권7호
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• pp.392-396
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• 2021

Expensive PCBN or ceramic cutting tools are used for processing of difficult-to-cut materials such as Ti and Ni alloy materials. These tools have the problem of breaking easily due to their high hardness but low fracture toughness. To solve these problems, cutting tools that form various coating layers are used in low-cost WC-Co hard material tools, and research on various tool materials is being conducted. In this study, binderless-WC, WC-6 wt%Co, WC-6 wt%Co-1 wt% Mo₂C, and WC-6 wt%Co-2.5 wt% Mo₂C hard materials are densified using horizontal ball milled WC-Co, WC-Co-Mo₂C powders, and spark plasma sintering process (SPS process). Each SPSed Binderless-WC, WC-6 wt%Co-1 wt% Mo₂C, and WC-6 wt%Co-2.5 wt% Mo₂C hard materials are almost completely dense, with relative density of up to 99.5 % after the simultaneous application of pressure of 60 MPa and almost no significant change in grain size. The average grain sizes of WC for Binderless-WC, WC-6 wt%Co-1 wt% Mo₂C, and WC-6 wt%Co-2.5 wt% Mo₂C hard materials are about 0.37, 0.6, 0.54, and 0.43 ㎛, respectively. Mechanical properties, microstructure, and phase analysis of SPSed Binderless-WC, WC-6 wt%Co-1 wt% Mo₂C, and WC-6 wt%Co-2.5 wt% Mo₂C hard materials are investigated.