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High Velocity Oxy-Fuel (HVOF) sprayed hardface coatings (i.e.: chromium carbide/nickel chromium) are widely used in the aircraft industry for severe wear environment. The hardface coatings have the ability to withstand different forms of wear such as abrasion, adhesion, fretting, and particle erosion. Major aircraft engine manufacturers and repair facilities use these coatings for both original engine manufacture (OEM) and for repair and overhaul of critical engine components which experience various types of wear. The objective of this study was to develop effective spray parameters for optimized coating properties using a statistical method known as Taguchi technique. The properties evaluated were coating hardness, bond strength, particle erosion, abrasive wear and microstructures. By using Taguchi Analysis the relationship between the various key parameters and coating properties can be determined.

An aluminum-silicon alloy/polyester abradable coating for clearance control applications (ie: first stage compressor seals of gas turbine engines) has been produced by using the Diamond Jet process, a High Velocity Oxy-Fuel (HVOF) system. The objective of this paper was to develop effective spray parameters for optimized coating properties for turbine fan case applications by using a statistical method known as Taguchi Analysis. The properties evaluated were coating hardness, bond strength and microstructure. By using Taguchi Analysis the relationship between the various key parameters and coating properties can be determined. For production verification of parameters developed by using Taguchi Analysis, a turbine fan casing was sprayed with the effective spray parameters. The results indicate that the fan case coating properties meet all the aerospace specification requirements.