Slurry Erosion Behaviour of HVOF Sprayed WC-10Ni-5Cr Coated 35CrMo Steel

Slurry erosion is a serious operational difficulty that results in severe equipment damage, downtime, and material replacement costs.To address this issue, the High Velocity Oxy Fuel (HVOF) spraying process is utilised to impart protective ceramic coatings to steel substrates, increasing their resistance to slurry erosion.In this investigation slurry erosion studies were carried out, with parameters such as rotating speed, impingement angle, slurry concentration, and exposure period being varied to understand their impact on erosion behaviour.Developed empirical correlations that accurately forecast coating mass loss using response surface methodology (RSM).A five-level central composite design matrix is used to optimize the experimental runs, resulting in a model with more than a 95% confidence level.Findings highlight the dominant influence of exposure time, followed by rotational speed, impact angle, and slurry concentrations on coating erosion rates.