Optimization of Cr3C2-NiCr Coatings using ID-HVOF: A Statistical Approach to Key Process Parameters

Abstract Cr 3 C 2 -NiCr coatings are widely used to protect industrial components in harsh environments due to their exceptional wear resistance, high-temperature oxidation protection, and corrosion resistance. Such coatings are typically produced using the high-velocity oxygen fuel (HVOF) spraying process. However, internal coating applications pose challenges such as restricted surface access, limited experience with optimized process parameters and the difficulty of producing fine chromium carbides, which results in coarser particles compared to powders like WC-CoCr. This study investigates the application of a commercially available Cr 3 C 2 -NiCr powder using the ID-HVOF coating process. A Central Composite Design (CCD) within a Design of Experiments (DoE) framework was employed to analyze the effects of key process parameters—kerosene, hydrogen, oxygen, and the powder feed rate—on the coating performance. The results confirm that the validation test successfully produced a coating that matches the predicted parameters from the CCD. This study underscores the importance of statistical design in optimizing the ID-HVOF process, enabling improved mechanical properties and reliable coating quality for the internal surface protection using Cr 3 C 2 -NiCr powders.