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<p>Slurry erosion still causes severe material degradation, limiting the service life and operation of hydraulic and slurry handling systems due to the impact of fluid-carried solid particles. Colmonoy-88 and Stellite-6 coatings were applied on substrates of SS-316 using the HVOF spraying technique to enhance their erosion-resistant performance. The dense microstructure with strong metallurgical bonding achieved by HVOF spraying significantly enhanced the surface hardness and reduced porosity, thus strengthening resistance to particle-induced wear. Slurry erosion tests were conducted using a jet erosion tester with different operational parameters: impact angle, particle velocity, particle size, erodent flux, and exposure duration. Scanning electron microscopy and energy-dispersive spectroscopy were carried out to characterize the surface morphology and elemental composition, respectively, and X-ray diffraction was performed to confirm the phase stability before and after erosion. The results showed that the erosion resistance is in the order of Colmonoy-88 &gt; Stellite-6 &gt; SS-316. Colmonoy-88 exhibited ductile wear features with crater and plowing mechanisms, whereas Stellite-6 showed microcracking and particle pull-out typical of brittle behavior. This study demonstrates that the HVOF process effectively enhances the erosion resistance of SS-316 through microstructural densification, carbide strengthening, and improved phase stability making it suitable for high-wear slurry environments.</p>

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Surface Damage and Degradation Mechanisms of HVOF-Sprayed Colmonoy-88 and Stellite-6 on SS-316 Under Slurry Erosion

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Ravi Shankar Kumar,
  • Satish Kumar

摘要

Slurry erosion still causes severe material degradation, limiting the service life and operation of hydraulic and slurry handling systems due to the impact of fluid-carried solid particles. Colmonoy-88 and Stellite-6 coatings were applied on substrates of SS-316 using the HVOF spraying technique to enhance their erosion-resistant performance. The dense microstructure with strong metallurgical bonding achieved by HVOF spraying significantly enhanced the surface hardness and reduced porosity, thus strengthening resistance to particle-induced wear. Slurry erosion tests were conducted using a jet erosion tester with different operational parameters: impact angle, particle velocity, particle size, erodent flux, and exposure duration. Scanning electron microscopy and energy-dispersive spectroscopy were carried out to characterize the surface morphology and elemental composition, respectively, and X-ray diffraction was performed to confirm the phase stability before and after erosion. The results showed that the erosion resistance is in the order of Colmonoy-88 > Stellite-6 > SS-316. Colmonoy-88 exhibited ductile wear features with crater and plowing mechanisms, whereas Stellite-6 showed microcracking and particle pull-out typical of brittle behavior. This study demonstrates that the HVOF process effectively enhances the erosion resistance of SS-316 through microstructural densification, carbide strengthening, and improved phase stability making it suitable for high-wear slurry environments.