Key Surface Roughness Parameters and Profilometer Set-Up for High Velocity Oxygen Fuel (HVOF) Coatings for Aerospace Applications

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Sohail Nassiri, sohail.j.nassiri@boeing.com, The Boeing Company Seattle; Wes Quigley, wes.w.quigley@boeing.com, The Boeing Company Seattle; 

Hexavalent chromium is a known carcinogen, but still widely used in the aerospace industry. Regulations, such as the Registration, Evaluation and Authorization and Restriction of Chemicals (REACH), by governmental agencies plan to restrict its use, which has driven focus towards hexavalent chrome alternatives. Thermal spray, a well-established technology, has proven to be a suitable replacement for hard chrome plating on many aerospace components. This paper is specifically geared towards high velocity oxygen fuel (HVOF) coatings which offer superior hardness, wear resistance and corrosion resistance given the strong adhesion, low porosity, and lack of microcracks. Given the increasing likelihood of HVOF replacing hard chrome plate in the near future, additional surface roughness parameters, such as the bearing ratio (often listed as Rmr or tp) may be vital to ensure the desired surface texture is achieved after grinding and/or superfinishing of HVOF coatings. In this study, proper set-up of profilometers will be demonstrated to ensure alignment with international standards such as SAE AMS2449 and AMS2452. In addition, the variance between different profilometer settings and hardware will be explored. A clear understanding of the appropriate specification callouts can only be achieved by understanding the needs of the surface preparation and the proper surface roughness parameters and settings to describe the desired surface reliably. 

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March 2026

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