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Intermetallic NiAl-Ta-Cr coatings were sprayed by the HVOF process. The effects of the spray parameters (including spray distance, oxygen and fuel flow rate etc.) on the microstructure and properties of coatings were investigated. Metallographic investigations and porosity measurements of the coatings were carried out by optical microscopy. The oxygen content of the coatings was measured by the LECO TC316 gas extract equipment. The results show that both the oxygen flow rate and the spray distance can significantly influence the properties of the coatings. The oxygen content in the coatings decreased with increasing the spray distance. A high O/H ratio led to a high degree of oxidation, a low porosity and more deposition. The coatings showed a homogeneous and dense structure, less porosities, and lower microhardness after heat-treated in a vacuum furnace at 1100 degrees C for 4 h. A continuous Al2O3 oxide scale formed on the surface of the coatings after the heat treatment at 1100 degrees C for 100 h. However, the microhardness of the coating slightly decreased as compared to that after vacuum annealing.
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