Research and Application of HVOF Sprayed NiCrFeMo Coatings

WU Lei; WANG Li; XU Feng; ZHANG Xiaofeng; LI Hongying; HUANG Xun; CHENG Siyuan; LIU Yapeng

doi:10.7643/issn.1672-9242.2025.07.013

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Equipment Environmental Engineering ›› 2025, Vol. 22 ›› Issue (7) : 96-104. DOI: 10.7643/issn.1672-9242.2025.07.013

Aviation and Aerospace Equipment

Research and Application of HVOF Sprayed NiCrFeMo Coatings

WU Lei^1,2, WANG Li^2,*, XU Feng¹, ZHANG Xiaofeng³, LI Hongying², HUANG Xun², CHENG Siyuan², LIU Yapeng²

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Abstract

The work aims to address the premature failure and economic losses of high-temperature alloy components in aviation engines due to substrate damage by conducting research on HVOF sprayed NiCrFeMo coatings. With a certain type of disc component from an aviation engine as the target for thermal spray repair, a three-factor and three-level orthogonal experiment was conducted to study the impact of key HVOF process parameters on coating performance. Minitab was used to evaluate the process capability index (CPK) of the optimal process parameters. When the hydrogen flow rate was 33.394 m³/h, the oxygen flow rate was 13.584 m³/h, and the spraying distance was 250 mm, these parameters were the best for repair and the coating had a uniform and dense structure, with a bonding strength to the substrate exceeding 62 MPa, and the process capability index was greater than 1.33, indicating high process stability. Using the optimal process parameters from this study to repair a defective disc component from an aviation engine yielded excellent results. After over 100 hours of field service, the coating showed no signs of cracking or peeling, and it bonded well to the substrate. The thickness change in the repaired area was less than 1%, and surface wear quality loss was minimal. HVOF can effectively repair defective high-temperature alloy components in aviation engines, ensuring high process stability and significantly extending the service life of the components.

Key words

HVOF / repair / NiCrFeMo / CPK / high-temperature alloy / bonding strength / aviation engines

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WU Lei, WANG Li, XU Feng, ZHANG Xiaofeng, LI Hongying, HUANG Xun, CHENG Siyuan, LIU Yapeng. Research and Application of HVOF Sprayed NiCrFeMo Coatings[J]. Equipment Environmental Engineering. 2025, 22(7): 96-104 https://doi.org/10.7643/issn.1672-9242.2025.07.013

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