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HVOF Coating Process Overview

HVOF feeds large volumes of combustible gases into a high-pressure combustion chamber, then through a long nozzle, producing a supersonic gas jet at 1525 to 1825 m/s (5000 to 6000 ft/s). Combustion temperatures range 2500 to 3100 °C (4500 to 5600 °F). Fuels include hydrogen, propylene, propane, acetylene, kerosene. This process yields dense, wellbonded coatings, favored for many applications. The extremely high gas velocity increases particle velocity, enhancing coating density and adhesion.

Components of HVOF System

  • Oxygen, fuel gas, and powder carrier gas circuits with high-volume supplies, highpressure hoses, flow regulators, and flashback arrestors
  • HVOF spray gun (torch body, combustion chamber, powder injector, nozzle)
  • Cooling circuits (water or air)
  • High-pressure powder feeder
  • Safety interlocks and console purging

Coating Characteristics

HVOF coatings rival detonation gun coatings, especially carbide and oxide types. Density, adhesion, and oxide content compare well to plasma coatings. Porosity is typically below 1%. Tungsten carbide/cobalt (WC/Co) coatings show minimal decomposition compared to plasma spray, preserving material hardness.

Benefits

  • Fine microstructure
  • Very dense and low porous coatings
  • High bond strength
  • Finishes to an extremely smooth surface
  • Optimal microhardness
  • Excellent corrosion properties
  • Excellent for hard metal (carbide coatings)
  • Low degree of oxidation

Typical Coatings

  • Cermets, carbides (tungsten carbide, chromium carbide)
  • Super alloys based on iron, nickel, and/or cobalt (Stellite, Triballoy, Inconel, Hastelloy, etc.)
  • Hard Chrome Replacement
  • MCrAlYs bond coatings under TBCs (Thermal Barrier Coatings)

Applications

  • Sealing moving surfaces to prevent seals from leaking
  • Improvement of wear resistance and chemical protection of ball valves
  • Protection of hydraulic piston rods against seawater environment in the offshore industry
  • Repairs and dimension corrections of worn drive shafts and bearing seatings
  • Substrate for Thermal Barrier Coatings (TBCs)
  • Cavitation protection in hydroelectric power stations
  • Protection of pump casings and impellers against chemical corrosion