Optimisation of the spray parameters for improved microstructural characteristics in the HVOF Sprayed Cr3C2-20(Ni20Cr) coating

Optimisation of the spray parameters for improved microstructural characteristics in the HVOF Sprayed Cr3C2-20(Ni20Cr) coating | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Optimisation of the spray parameters for improved microstructural characteristics in the HVOF Sprayed Cr 3 C 2 -20(Ni20Cr) coating Hariharan Venkataraman, Vishal Uttamrao Bagade, Biju V. M., SSK Balam, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5906616/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 12 Feb, 2026 Read the published version in Journal of Materials Science: Materials in Engineering → Version 1 posted You are reading this latest preprint version Abstract Wear resistance coating of Cr 3 C 2 -20(Ni20Cr) is required to be sprayed through High Velocity Oxy Fuel (HVOF) Spray Process on the compressor disc of aero gas turbine engine. The part is made up of Ti6Al4V alloy. While employing the spray parameters recommended by Original Equipment Manufacturer (OEM) for preliminary deposition trials, microstructural defects in the form of vertical cracks were observed. In order to overcome the above microstructural defects, various efforts were sequentially carried out. The initial approach of preheating the substrate at 120°C is aimed at reducing the thermal gradient between the substrate and coating which exhibited partial success. Detailed investigation involving design of experiment using Taguchi L16 Orthogonal array is employed to study the effect of certain critical parameters such as standoff distance, powder feed rate, hydrogen flow rate and Oxygen flow rate. TOPSIS method is used to establish the optimal coating parameters to achieve the crack free coating with the acceptable hardness, porosity and oxide levels. From the above studies, standoff distance 150mm, feed rate 25 g/min, hydrogen flow rate 470 NLPM and Oxygen flow rate 205 NLPM are optimised for crack free HVOF coating of Cr 3 C 2 -20(Ni20Cr) on Ti6Al4V substrate and the coating microstructure with the required hardness and the oxides & porosity levels in acceptable range is established for actual component manufacturing. Vertical crack TOPSIS Wear resistance HVOF Optimisation Full Text Cite Share Download PDF Status: Published Journal Publication published 12 Feb, 2026 Read the published version in Journal of Materials Science: Materials in Engineering → Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5906616","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":411341455,"identity":"09abc2d9-b764-4fa6-8db0-f9748f125726","order_by":0,"name":"Hariharan Venkataraman","email":"","orcid":"","institution":"Gas Turbine Research Establishment","correspondingAuthor":false,"prefix":"","firstName":"Hariharan","middleName":"","lastName":"Venkataraman","suffix":""},{"id":411341456,"identity":"51a67e8a-b3d3-41c1-abfb-29a7238845b5","order_by":1,"name":"Vishal Uttamrao Bagade","email":"","orcid":"","institution":"Gas Turbine Research Establishment","correspondingAuthor":false,"prefix":"","firstName":"Vishal","middleName":"Uttamrao","lastName":"Bagade","suffix":""},{"id":411341457,"identity":"e813fe0e-24f0-491a-9942-0f8f2df3072f","order_by":2,"name":"Biju V. 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