HVAF Flash-Carbide:
A High Performance, Economical Alternative To Electroplated Hard Chrome

Flash-Carbide is hard (over 1400 HV300) and very dense coating of WC-10Co-4Cr composite material, applied with Kermetico High-Velocity Air-Fuel (HVAF) spray method onto various metallic parts and structures to improve their surface resistance to severe wear and corrosion.

The Flash-Carbide coating:

thickness is comparable to dimensional tolerances of the treated parts (15-35 micron)
small thickness deviation, about 1 micron,
as-sprayed surface roughness is similar to ground surface, typically Ra =1.5 micron or lower.

Thus, the Flash-Carbide surface does not require dimensional grinding. Final surface roughness is achieved with a simple polishing.

Cross-sectional micrographs of Electroplated Hard Chrome EHC (a) and Flash-Carbide (b) coatings

Micrograph images is a courtesy of GE Global Research, Niskayuna NY USA

Coating is dense to meet industry specifications for corrosion resistance (typically set as duration without traces of corrosion during salt-spray corrosion testing).
Mechanical properties, such as fatigue resistance, wear and erosion resistance, impact resistance, etc. exceed existing values for Electroplated Hard Chrome.

When coating cylindrical parts, such as hydraulic rods, pump plungers and shafts, the sprayed-and-finished Flash-Carbide cost drops below 0.04 USD per sq.cm (under 37 USD per sq. foot), which is 10…20 -times lower than typical HVOF carbide coating.

Flash-Carbide:

Survives 1000-hr salt spray corrosion test at as-sprayed thickness as low as 15 microns

Flash-Carbide: ASTM B117 Salt Spray Corrosion Test

AK06 HVAF WC-10Co4Cr: 25 µm (0.0010“) thickness as-sprayed

Flash-Carbide: ASTM B117 Salt Spray Corrosion Test

AK06 HVAF WC-10Co4Cr: 15 µm (0.0006“) thickness as-sprayed

Flash-Carbide:

Wear resistance exceeds electroplated chrome by 20+ fold

Flash-Carbide: ASTM G174 Loop Abrasion Test

Test results is a courtesy of GE Global Research, Niskayuna NY USA

Flash-Carbide (FC):
Abrasive Wear Test vs Electroplate Hard Chrome (EHC)

Test results is a courtesy of Prof. Li Changxin, Xian Jiatong University, China
Abrasive Wheel (400 mm Al2O3) Diameter 210 mm, rotation 97 RPM, Load 25N, duration 1 min