Microstructure and Tribological Properties of HVOF-sprayed Inconel 718 Coatings

YANG Shuhan; XIAO Yao; MA Lixia; HE Dingyong; XU Yi; YU Jinman

doi:10.16490/j.cnki.issn.1001-3660.2026.05.010

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Surface Technology ›› 2026, Vol. 55 ›› Issue (5) : 122-133. DOI: 10.16490/j.cnki.issn.1001-3660.2026.05.010

Friction, Wear and Lubrication

Microstructure and Tribological Properties of HVOF-sprayed Inconel 718 Coatings

YANG Shuhan¹, XIAO Yao², MA Lixia^1,*, HE Dingyong^1,3,*, XU Yi⁴, YU Jinman⁴

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Abstract

As key control components in aerospace pipeline systems, ball valves face severe friction and wear under high-pressure conditions, leading to deterioration in airtightness and reliability. To overcome the wear resistance limitations of SUS 300-series stainless steels, this study employs High Velocity Oxy-Fuel (HVOF) spraying to apply Inconel 718 coatings on SUS 304 substrates and systematically investigates their microstructural evolution and influence on mechanical and tribological performance.
This study uses 30-60 mesh white alumina (aluminum oxide) as the abrasive for sandblasting treatment of SUS 304 substrates. The surface is roughened under compressed air pressure of 0.5-0.6 MPa and a spraying distance of 30-40 mm, achieving a surface roughness of ≥5 μm. The HVOF spraying is conducted with kerosene as the fuel at the following parameters: oxygen pressure of 0.9 MPa, flow rate of 2 000 L/min, fuel pressure of 0.84 MPa, flow rate of 5.9 g/h, powder feed rate of 58 g/min, and a spraying distance of 380 mm. Using these parameters, HVOF-sprayed Inconel 718 coatings with an average thickness of 464.2 μm and no apparent defects is produced. The microstructure of the coatings is characterized by virtue of advanced techniques such as Optical Microscope (OM), Scanning Electron Microscopy (SEM), Energy Dispersive Spectrometer (EDS) Electron Backscatter Diffraction (EBSD), X-ray Diffraction (XRD) and Transmission Electron Microscope (TEM). The microhardness of the coatings is tested with a Vickers hardness tester under a load of 100 g and a dwell time of 15 s. A reciprocating friction and wear test is conducted on the polished coating surface with a material surface performance tester, and the dynamic coefficient of friction is recorded. A Si₃N₄ ball with a diameter of 5 mm is selected, with a normal load of 20 N, sliding speed of 500 r/min, single stroke length of 5 mm, and a test duration of 30 min. Subsequently, laser confocal analysis is conducted to examine the morphology parameters of the wear track.
The experimental results show that the porosity of the coatings is at an excellent level, with a value of only 0.43%. During the HVOF process, oxides mainly consisting of chromium oxide form on the surface of the particles, which then lead to pore formation during the subsequent deposition process. The coatings comprise fine grains averaging 2.26 μm and exhibit a high density of geometrically necessary dislocations, reaching 22.46×10¹⁴ m^‒2. Simultaneously, nanoscale γ' and δ strengthening phases are precipitated. Fine grains block dislocation motion by increasing grain boundary density; nanoscale precipitates trigger Orowan strengthening, hindering dislocation glide; and the high dislocation density enhances work hardening and promotes entanglement. Moreover, the coatings also have a residual compressive stress of up to ‒798.7 MPa. This multiscale synergy raises the coatings' microhardness to 550.7HV0.1, a 126.72% improvement over the substrate's 242.9HV0.1. Bonding strength test results indicate that the coatings are tightly bonded to the substrate, with an average bonding strength as high as 61.79 MPa. Friction and wear tests indicate that the coatings' average coefficient of friction (0.72) is significantly lower than that of the substrate (0.82); the wear track width (910.2 μm) and depth (31.1 μm) are reduced by 25.32% and 53.86%, respectively, and the volumetric wear rate decreases to 1.74×10^‒6 mm³/(N·m), reflecting a wear resistance improvement of approximately 52.59%.
The findings demonstrate that HVOF-sprayed Inconel 718 coatings substantially improve the surface hardness and wear resistance of ball valves, supporting the durability design of aerospace high-pressure pipeline components.

Key words

ball valve / HVOF / Inconel 718 coatings / microstructure / microhardness / wear resistance

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YANG Shuhan, XIAO Yao, MA Lixia, HE Dingyong, XU Yi, YU Jinman. Microstructure and Tribological Properties of HVOF-sprayed Inconel 718 Coatings[J]. Surface Technology. 2026, 55(5): 122-133

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