HVOF Coating
HVOF coating services deliver high-density, wear-resistant, and corrosion-resistant coatings for industrial components requiring extreme performance. Contact us to discuss your project and request a quote.
HVOF Coatings Overview
High Velocity Oxygen Fuel (HVOF) coating is a thermal spray coating process used to improve or restore a component’s surface properties or geometry. This surface engineering technique extends equipment life by increasing erosion and wear resistance as well as corrosion protection.
HVOF spraying was developed in the 1980s as a subset of thermal spraying. The process works by mixing fluid fuel and oxygen, which is fed into a combustion chamber and ignited. The resulting gas has an extremely high temperature and pressure, which is ejected through a nozzle at supersonic speeds. Powder is injected into the high-velocity gas stream, where it partially melts and is directed toward the surface to be coated.
HVOF coatings are characterized by a dense structure with low porosity (1–2 vol%), low oxide content (1–2 wt%), and high bond strength (often exceeding 80 MPa). These features provide excellent wear resistance, corrosion protection, and durability.
Common Coating Materials
HVOF spraying supports a wide range of materials, allowing flexibility depending on performance requirements:
- Cermets (e.g. WC/Co, WC/Co/Cr, Cr 3C 2/NiCr, NiCrSiBC)
- Ceramics (e.g. Cr 2O 3, Al 2O 3, ZrO 2)
- Metal alloys (e.g. steels, nickel, chromium and cobalt alloys including NiCrSiB and MCrAlYs)
- Pure metals (e.g. Ni, Cu, Al, Mo, Ti)
- Polymers (e.g. polyester, nylon)
- Composites (e.g. Ni-graphite)
Key Benefits of HVOF Coating
HVOF coatings provide a wide range of mechanical and functional benefits:
- High hardness, durability, and toughness
- Abrasion and erosion resistance
- Corrosion resistance in many environments
- Fretting and anti-galling properties
- Long-lasting traction surfaces
Advantages over other coating methods include:
- Higher density and lower porosity due to greater particle impact velocities
- Higher bond strength and cohesive strength within the coating
- Lower oxide content due to reduced in-flight exposure
- Retention of powder chemistry at high temperatures
- Smoother as-sprayed surfaces
- Superior wear resistance and hardness
- Improved corrosion protection due to reduced porosity
- Ability to build thicker coatings with less residual stress
Applications of HVOF Coatings
One of the most commonly applied coatings is tungsten carbide 86/10/4 (86% Tungsten Carbide, 10% Cobalt & 4% Chromium). Typical applications include:
- Seal areas on shafts
- Ball and gate valves
- Hydraulic rams
- Pump seals
- Industrial components requiring hard chrome replacement
HVOF spraying is primarily used to apply high-quality coatings of cermets such as WC/Co and WC/Co/Cr. Coating thickness typically ranges from 2.0–40.0+ mil DFT (0.002”–0.040”). These coatings enhance the performance of cost-effective, lightweight, or base materials by adding a functional surface layer.
This coating achieves hardness levels of 1200–1400 Vickers and operates effectively at temperatures up to 500°C (932°F). It provides exceptional hardness, wear resistance, and corrosion protection. However, it is not suitable for high-pH environments or hydrofluoric acid solutions.
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HVOF Coating FAQs
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HVOF coatings are widely used in oil & gas, aerospace, power generation, mining, pulp and paper, and general industrial applications where components are exposed to severe wear, erosion, or corrosion.
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Yes. While highly durable, certain HVOF coatings (like tungsten carbide) are not suitable for high-pH environments or hydrofluoric acid exposure. Coating selection must match the operating environment.
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Most HVOF coatings operate effectively up to 500°C (932°F), though performance may vary based on coating material and application.
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Yes. Tungsten carbide HVOF coatings are often used as an environmentally friendly and higher-performance alternative to hard chrome plating, especially for hydraulic rams, pump components, and valve surfaces.