The demand for high performing damage tolerant coatings in engineered systems has provided a platform for a wide variety of coating materials and processes to emerge in industrial uses. One of the most prominent to emerge are High Velocity Oxy-Fuel (HVOF) sprayed Cemented Carbide Coatings (WC Co, WC CoCr, CrC NiCr), finding applications in aerospace, earthmoving, and others. The complexity involved with the HVOF coating process and application specific qualification testing leads to a lengthy process for optimizing a particular coating, with little insight into the properties link between the process and performance.|
This paper uses the methodology of Process Mapping to establish the links between processing, properties, and performance of HOVF deposited Damage Tolerant Coatings. Using particle diagnostics, In-situ curvature stress, Modulus, Hardness, and Fracture Toughness measurements, the processing conditions and subsequent stress state and properties can be correlated and mapped out. Properties of cemented carbide coatings can then be describe in Ashby-type charts, where coating process and material can be chosen for particular applications, where necessary performance testing can be applied. This work provides the framework for fundamental understanding the macroscopic properties of cemented carbide coatings and allow for a robust method for optimizing coatings based on application.