Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps

Tommi Varis (Corresponding Author), Tomi Suhonen, A. Ghabchi, A. Valarezo, S. Sampath, X. Liu, S.-P. Hannula

    Research output: Contribution to journalArticleScientificpeer-review

    30 Citations (Scopus)

    Abstract

    Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.
    Original languageEnglish
    Pages (from-to)1009-1018
    Number of pages10
    JournalJournal of Thermal Spray Technology
    Volume23
    Issue number6
    DOIs
    Publication statusPublished - 2014
    MoE publication typeA1 Journal article-refereed

    Fingerprint

    coatings
    Coatings
    residual stress
    Residual stresses
    wear resistance
    Wear resistance
    hardness
    Cermet Cements
    mechanical properties
    Hardness
    tungsten carbides
    Mechanical properties
    Damage tolerance
    lamella
    fracture strength
    Tungsten carbide
    linkages
    carbides
    coating
    modulus of elasticity

    Keywords

    • coatings
    • fracture toughness
    • HVOF
    • process maps
    • residual stress
    • ProperTune

    Cite this

    Varis, Tommi ; Suhonen, Tomi ; Ghabchi, A. ; Valarezo, A. ; Sampath, S. ; Liu, X. ; Hannula, S.-P. / Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings : An Approach Toward Process Maps. In: Journal of Thermal Spray Technology. 2014 ; Vol. 23, No. 6. pp. 1009-1018.
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    title = "Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings: An Approach Toward Process Maps",
    abstract = "Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.",
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    author = "Tommi Varis and Tomi Suhonen and A. Ghabchi and A. Valarezo and S. Sampath and X. Liu and S.-P. Hannula",
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    Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings : An Approach Toward Process Maps. / Varis, Tommi (Corresponding Author); Suhonen, Tomi; Ghabchi, A.; Valarezo, A.; Sampath, S.; Liu, X.; Hannula, S.-P.

    In: Journal of Thermal Spray Technology, Vol. 23, No. 6, 2014, p. 1009-1018.

    Research output: Contribution to journalArticleScientificpeer-review

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    T1 - Formation Mechanisms, Structure, and Properties of HVOF-Sprayed WC-CoCr Coatings

    T2 - An Approach Toward Process Maps

    AU - Varis, Tommi

    AU - Suhonen, Tomi

    AU - Ghabchi, A.

    AU - Valarezo, A.

    AU - Sampath, S.

    AU - Liu, X.

    AU - Hannula, S.-P.

    PY - 2014

    Y1 - 2014

    N2 - Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.

    AB - Our study focuses on understanding the damage tolerance and performance reliability of WC-CoCr coatings. In this paper, the formation of HVOF-sprayed tungsten carbide-based cermet coatings is studied through an integrated strategy: First-order process maps are created by using online-diagnostics to assess particle states in relation to process conditions. Coating properties such as hardness, wear resistance, elastic modulus, residual stress, and fracture toughness are discussed with a goal to establish a linkage between properties and particle characteristics via second-order process maps. A strong influence of particle state on the mechanical properties, wear resistance, and residual stress stage of the coating was observed. Within the used processing window (particle temperature ranged from 1687 to 1831 °C and particle velocity from 577 to 621 m/s), the coating hardness varied from 1021 to 1507 HV and modulus from 257 to 322 GPa. The variation in coating mechanical state is suggested to relate to the microstructural changes arising from carbide dissolution, which affects the properties of the matrix and, on the other hand, cohesive properties of the lamella. The complete tracking of the coating particle state and its linking to mechanical properties and residual stresses enables coating design with desired properties.

    KW - coatings

    KW - fracture toughness

    KW - HVOF

    KW - process maps

    KW - residual stress

    KW - ProperTune

    U2 - 10.1007/s11666-014-0110-5

    DO - 10.1007/s11666-014-0110-5

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    SN - 1059-9630

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