The effects of coating parameters were investigated in wear resistance coatings of Diamalloy-406 on Inconel 718 to obtain an optimum coating condition by high velocity oxy-fuel spraying. The coating parameters, the flow rates of source gases (hydrogen and oxygen), the powder feed rate, and the spray distance, were designed by the Taguchi method. The optimal conditions were determined: oxygen flow rate 34 FRM, hydrogen flow rate 57 FRM, powder feed rate 35 g/min, and spray distance 7 inch. Friction coefficients of the coating and the substrate decreased with an increasing sliding surface temperature from 25 oC to 450 oC. The friction coefficient of Diamalloy-4006 coating decreased as the sliding surface temperature increased from 0.43 ± 0.01 at 25 oC to 0.29 ± 0.01 at 450 oC. The wear trace and wear depth of the coating were smaller than the substrate at all temperatures tested. The relationship between spray parameters and wear resistance was discussed extensively, based on the measured roughness, hardness, and porosity in each coating.

[ ] powders were thermally sprayed onto mild steel substrates in air and under a reduced pressure of argon. Several oxides were formed after thermally-spraying the mechanically-alloyed powders in air. After spraying in a reduced pressure of argon, the coating layers obtained from the gently mixed powders consisted of the elemental metals, but an amorphous phase primarily appeared in the thermally-sprayed mechanically-alloyed powders, which transformed into the icosahedral quasicrystal phase and a minor crystal phase after annealing at 828 K. The Vickers hardness and the contact angle with pure water for the quasicrystal layers were about 7 GPa and respectively.

[ ] composite powders were produced by high energy mechanical milling of a mixture of Al and powders followed by a combustion reaction. The powders were subsequently thermally sprayed on H13 steel substrates. Microstructural examination was conducted on the composite powders and thermally sprayed coatings, using X-ray diffractometry (XRD) and scanning electron microscopy (SEM). The performance of the coatings was evaluated in terms of micro-hardness and thermal fatigue. The thermally sprayed coatings performed very well in the preliminary thermal fatigue tests and showed no wetting tendency to molten aluminum.

Plasma 용사된 단열피복에 내재하는 기공의 크기, 형상 및 분포는 피복층 자체의 물성에 지대한 영향을 미치므로 이를 용사변수에 따라 조사하였다. MgO 안정화 지르코니아 피복시 도입되는 기공은 미세기공 외에 각각 생성기구가 다른 조대한 기공 즉 구형과 불규칙한 기공, 그리고 crack으로 구성되었다. 용사거리에 따라 기공의 생성과정과 특성이 변하였으며 Plasma 전류 및 가스 유량의 증가에 의해서 기공도는 감소하는 경향을 보였다. Plasma 가스가 N2인 경우가 Ar보다 더 높은기공도를 보였고 전체적으로 단열피복의 기공도는 10~18%였다. Scratch test로 측정된 단열피복층의 상대적인 경도는 기공도와 높은 상관관계를 보였다.

Thermal spray coatings and organic coatings are often individually used in corrosion protection of steel structures. Duplex coating systems of thermally sprayed metal coating combination with organic coating represent a new generic type of coatings on offshore steel structures under the highly corrosive environments. In this study, weathering test were carried out on four types of duplex coated specimens; thermally sprayed metals of zinc, zinc-aluminum alloy, aluminum and aluminum-magnesium alloy in combination with painting of acrylic urethane. From the test results, weathering performance of the duplex coating systems were evaluated.