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Effect of Feedstock Size and its Distribution on the Properties of Detonation Sprayed Coatings

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Abstract

The detonation spraying is one of the most promising thermal spray variants for depositing wear and corrosion resistant coatings. The ceramic (Al2O3), metallic (Ni-20 wt%Cr) , and cermets (WC-12 wt%Co) powders that are commercially available were separated into coarser and finer size ranges with relatively narrow size distribution by employing centrifugal air classifier. The coatings were deposited using detonation spray technique. The effect of particle size and its distribution on the coating properties were examined. The surface roughness and porosity increased with increasing powder particle size for all the coatings consistently. The feedstock size was also found to influence the phase composition of Al2O3 and WC-Co coatings; however does not influence the phase composition of Ni-Cr coatings. The associated phase change and %porosity of the coatings imparted considerable variation in the coating hardness, fracture toughness, and wear properties. The fine and narrow size range WC-Co coating exhibited superior wear resistance. The coarse and narrow size distribution Al2O3 coating exhibited better performance under abrasion and sliding wear modes however under erosion wear mode the as-received Al2O3 coating exhibited better performance. In the case of metallic (Ni-Cr) coatings, the coatings deposited using coarser powder exhibited marginally lower-wear rate under abrasion and sliding wear modes. However, under erosion wear mode, the coating deposited using finer particle size exhibited considerably lower-wear rate.

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Acknowledgments

The authors are grateful to Centre for Engineered Coatings Group for assisting in generation of the coated specimens and also to Material Characterization Group for kind assistance. The authors also thank the reviewers of this paper for their constructive comments which have certainly improved the quality.

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Authors and Affiliations

  1. International Advanced Research Center for Powder Metallurgy and New Materials (ARCI), Balapur (P.O), Hyderabad, 500 005, India

    P. Suresh Babu, D. S. Rao, G. V. N. Rao & G. Sundararajan

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  1. P. Suresh Babu
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  2. D. S. Rao
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  3. G. V. N. Rao
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  4. G. Sundararajan
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Correspondence to G. Sundararajan.

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Suresh Babu, P., Rao, D.S., Rao, G.V.N. et al. Effect of Feedstock Size and its Distribution on the Properties of Detonation Sprayed Coatings. J Therm Spray Tech 16, 281–290 (2007). https://doi.org/10.1007/s11666-007-9032-9

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  • DOI: https://doi.org/10.1007/s11666-007-9032-9

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