Sreerag, M.P.Abhijith Vijay, V.Babu, N.N.Ali, S.S.Cadambi, S.Rajasekaran, B.2026-02-032025Journal of Materials Engineering and Performance, 2025, , , pp. -10599495https://doi.org/10.1007/s11665-025-12902-yhttps://idr.nitk.ac.in/handle/123456789/20578This study explores the efficacy of high velocity air fuel (HVAF) spraying for repairing worn-out IN718 thrust collars used in the chemical industry. We investigated the characteristics and application potential of thick IN718 depositions for surface restoration, focusing on their adhesion. To evaluate microstructure and adhesion, approximately 2-mm-thick IN718 layers were deposited onto IN718 wrought coupons. The HVAF-sprayed layers were notably dense (99.5%) and exhibited excellent hardness, reaching 450 HV0.3, which suggests superior mechanical properties compared to the bulk material. A three-point bending test was conducted to assess the adhesion strength of these thick deposits. The results demonstrated excellent adhesion in both compressive (1281 MPa with > 2% strain) and tensile bending. Trusting in these promising substrate-layer interfacial adhesion characteristics, the investigation was extended to demonstrate the refurbishment of an actual worn-out industrial IN718 thrust collar. A 2-mm-thick IN718 deposition was applied to the entire worn area, and excess material was subsequently machined to achieve the desired surface finish for reuse. Overall, HVAF spray technology shows significant promise for developing thick metallic layers with excellent interfacial adhesion, providing a robust and viable solution for effectively refurbishing heavily worn metallic components and extending their service life. © ASM International 2025.AirBending strengthChemical industryFuel additivesRestorationTensile strengthThermal sprayingBulk materialsHigh velocity air fuelsInterfacial adhesionsMechanicalPropertySubstrate layersSurface-modificationThermalsprayThick depositThree-point bending testSurface treatment