SBIR Phase I: Kinetic Metallization of Chromium-Carbide Cermet Coatings with Superior Wear Resistance

该小型企业创新研究（SBIR）第一阶段项目将开发一种应用碳化铬金属陶瓷涂层的创新方法，而不会降低高温热喷涂工艺经常引起的涂层质量。 碳化铬金属陶瓷涂层通常采用高速氧燃料（HVOF）或高速空气燃料（HVAF）方法。最近的研究表明，碳化物相溶解到基体中降低了这些涂层的硬度和耐腐蚀性。 本研究的目的是探讨使用低温动力学金属化（KM）工艺应用碳化铬金属陶瓷涂层，以克服这些局限性的可行性。 KM沉积工艺的成功实施预计需要合适的原料粉末;因此，该项目将首先研究用各种基质材料制造碳化铬金属陶瓷粉末以生产超细粉末的专有方法。这些超细碳化铬金属陶瓷粉末将使用KM工艺沉积在各种基材上，包括钢、钛和氧化铝。 将对涂层的机械和冶金性能（包括耐磨性）进行检查，并与热喷涂涂层进行比较，以获得改进的性能。 预计该技术将为发电行业的高温应用提供上级耐磨和耐腐蚀涂层，并为医疗行业提供改进的生物相容性涂层。

This Small Business Innovation Research (SBIR) Phase I project will develop an innovative method of applying chromium-carbide cermet coatings without degradation in coating quality frequently induced by high-temperature thermal spray processes. Chromium-carbide cermet coatings are usually applied with high velocity oxy-fuel (HVOF) or high velocity air-fuel (HVAF) methods. Recent work has demonstrated that dissolution of the carbide phase into the matrix degrades the hardness and corrosion resistance of these coatings. The objective of the research is to investigate the feasibility of using the low temperature Kinetic Metallization (KM) process for applying chromium-carbide cermet coatings to overcome these limitations. Successful implementation of the KM deposition process is expected to require suitable feedstock powders; hence the project will initially investigate proprietary methods for fabricating chromium-carbide cermet powders with various matrix materials to produce ultra-fine powders. These ultra-fine chromium-carbide cermet powders will be deposited on various substrates including steel, titanium, and alumina using the KM process. Mechanical and metallurgical properties including wear resistance of the coatings will be examined and compared to thermal sprayed coatings to access the improved performance. It is anticipated the technology will enable superior wear and erosion resistant coatings for the high temperature applications in the power generation industry and improved biocompatible coatings for the medical industry.