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Mechanical engineering

Comparative Investigation of High-Velocity Oxy Fuel and Plasma Coating Processes on Mechanical and Wear Properties of Iron Alloy-based Coating Materials

Strategic Insights

— 2 min read

Research published in the Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering has compared the effectiveness of two thermal spray deposition methods on the mechanical and wear properties of iron alloy-based coatings on ZE41 magnesium alloys. The study found that high-velocity oxy fuel (HVOF) coating resulted in a more homogeneous and dense micro-structure, better hardness, and lower wear rate compared to plasma spray system (PSS) coating. The HVOF coating showed a porosity of 0.97%, micro-hardness of 689.63 HV0.3, and adhesive pull-off strength of 20.06 MPa, whereas the PSS coating had a lamellar structure with many pores and micro-cracks, a lower micro-hardness of 526 HV0.3, and a weaker bonding strength of 12.17 MPa.

Key Takeaways:

  • The HVOF coating method resulted in a 741% higher hardness compared to the substrate ZE41, while the PSS coating showed a 541% higher hardness.
  • The wear rate of the HVOF coating was 18.4% less than the PSS coating.
  • The HVOF coating had a homogeneous and dense micro-structure, whereas the PSS coating had a lamellar structure with many pores and micro-cracks.
  • The adhesive pull-off strength of the HVOF coating was 68.8% higher than the PSS coating.
  • The study suggests that HVOF coating provides excellent micro-structure, uniform density, better hardness, and low wear rate compared to plasma coating.
  • The research has been peer-reviewed and published in a reputable journal.
  • The study highlights the potential of HVOF coating in mechanical and wear applications.
  • Various mechanical and wear parameters, including micro-hardness and adhesive pull-off strength, were used to evaluate the effectiveness of both coating methods.

Statistics:

  • The porosity of the HVOF coating was 0.97%, while the porosity of the PSS coating was 1.21%.
  • The micro-hardness of the HVOF coating was 689.63 HV0.3, whereas the micro-hardness of the PSS coating was 526 HV0.3.
  • The adhesive pull-off strength of the HVOF coating was 20.06 MPa, whereas the adhesive pull-off strength of the PSS coating was 12.17 MPa.
  • The hardness of the HVOF coating was 740% more than the hardness of the substrate ZE41.
  • The wear rate of the HVOF coating was 18.4% less than the wear rate of the PSS coating.

Sources:

  • Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2025.
  • Sage Publications Ltd, 1 Olivers Yard, 55 City Road, London EC1Y 1SP, England.
  • Bhagalpur Coll Engn, Dept. of Mechanical Engineering, Bhagalpur, India.
  • NewsRx. Researchers from Department of Mechanical Engineering Describe Findings in Mechanical Engineering (Comparative Investigation of High-velocity Oxy Fuel and Plasma Coating Process On Mechanical and Wear Properties of Iron Alloy-based Coating ...). Journal of Engineering. October 20, 2025; p 3423.

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