Removal of HVOF and other Plasma Sprayed Metallic Coatings Using Ultrasonically Produced Forced Pulsed Waterjets

"Plasma or thermal sprayed coatings are becoming more widely used in a wide range of industrial applications. The preference to use thermal sprayed coatings is mainly attributed to its superior wear, and corrosion resistant properties akin to hard chrome but without the harmful health implications of chrome in the coating process. Specifically, High Velocity Oxygen Fuel (HVOF) plasma sprayed Tungsten Carbide & Cobalt (WC/Co) coatings are presently being tested on aircraft landing gear. This coating can be efficiently applied and is highly resistant to corrosion and wear. However, HVOF coating's durability also makes it difficult to be stripped for inspection and overhaul. Current coating removal methods usually involve a multi-step process whereby the coating must undergo diamond wheel grinding, chemical dipping, grit blasting, ultrahigh pressure (UHP) 380 MPa (55 Kpsi) water blasting, and subsequent chemical dipping, depending on the type and thickness of the coating. As explained by Yan, et al [l]"" a unique method has been developed for removing HVOF coatings with the use of only water. The method consists of modulating a stream of water at a pressure of only 69 MPa (10 Kpsi) with ultrasonic waves to generate a forced pulsed waterjet. The resulting cyclic loading of the hard coating due to the impact of the water pulses easily causes it to flake off the substrate. This paper will briefly describe the fundamentals of the forced pulsed waterjet technique with an emphasis on insitu applications of the removal of various plasma and HVOF coatings."