Correlation between particle size and porosity of Fe-based amorphous coating

ABSTRACT

The relationship between the particle size and porosity of an Fe-based amorphous coating that is fabricated using a high-velocity oxygen fuel (HVOF) process was revealed by both numerical and experimental methods. A computational fluid dynamics model was implemented in order to understand the gas-flow field and the behaviour of in-flight particles with different particle sizes during the HVOF spray process. By analysing both particle velocity and temperature, the optimal particle size range (20–30 μm) to achieve low-porosity coatings was predicted. These calculations were experimentally verified by the production of a low porosity (0.95%), Fe-based amorphous coating that was fabricated by HVOF using the predicted optimal particle size.

KEYWORDS:

• Fe-based amorphous coating
• porosity
• HVOF
• computational simulation
• particle size

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This work was supported by the National Key Research and Development Program of China under Grant No. 2016YFB1100204; National Natural Science Foundation of China under Grant Nos. 51471166 and 51701090; China Postdoctoral Science Foundation; National Natural Science Foundation of Liaoning Province of China under Grant No. 201601332; Educational Commission of Liaoning Province of China under Grant No. L2017LQN025; Scientific Research Cultivation Fund of LSHU under Grant No. 2016PY-023; and Research Initiation Funds for LSHU under Grant No. 2016XJJ-043.