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In order to improve the environmental barrier property of coatings fabricated by the HVOF spray process with a gas shroud, their oxygen content of 0.19 mass % as the lowest conventional figure was still more reduced by changing the composition of combustion gas. Introduction of nitrogen gas to the combustion chamber lowered the temperature of the in-flight spray particles while maintaining their high velocity. This method could reduce the oxygen level of a HastelloyC coating to 0.063 mass% at the lowest presort value, which is comparable to that of the feedstock with 0.042 mass%. Other coating with 0.14 mass% could be obtained along with the open porosity below 0.1 vol%. The latter coating exhibited the improved environmental barrier property in artificial seawater.

Oxidation Restriction of In-flight Particles upon GS-HVOF Spraying by Nitrogen Addition to Combustion Gas