Abstract
Arc spraying is a cost-effective technology, which is determined by a few key factors. It is already established for corrosion protection of large structures and thus considered for restoration of eroded ship rudders and propellers by depositing typical propeller materials. The main parameters like arc current, gas type/flow or process kinematics strongly influence the residual stresses in these coatings, which in turn affect coating properties. In past investigations, it was shown that this impact could be modified by using alternative gas mixtures or changing the heat input in the process. However, the mentioned studies neglect the influence of the substrate, since solely steel substrates were used. In consequence, propeller alloys CuAl9Ni5Fe4Mn (Ni-Al bronze) and CuMn13Al8Fe3Ni2 (Mn-Al bronze) were now arc-sprayed onto bronze substrates while using the same parameters and kinematics as in the past. For reproducible results, the residual stresses within the coatings were measured by novel incremental hole drilling method based on electronic speckle pattern interferometry (ESPI) and correlated with the other coating properties. In comparison with spraying onto steel, the same conditions led to reduced Young’s moduli, lower tensile stresses and improved cavitation erosion resistance, while other properties like hardness and electrical conductivity showed varying trends.
Highlights
Propellers of high-speed ships experience severe damages by wear, which are mainly caused by corrosion and erosion within aggressive saltwater and dissolved sediments
The results of this study will be compared to the former results on steel substrates, which can be found in detail in Ref 21
The following analyses of the present study are compared to former results on steel substrates, which can be found in detail in Ref 21
Summary
Propellers of high-speed ships experience severe damages by wear, which are mainly caused by corrosion and erosion within aggressive saltwater and dissolved sediments. Cavitation erosion plays an important role regarding erosion (Ref 1). The phenomenon is described as the material loss due to the formation and collapse of vapor bubbles by pressure oscillations on the corresponding surfaces (Ref 2). Hydrodynamic calculations are carried out in the design phase of ship construction to improve propeller–rudder interactions and minimize cavitation. Erosive damage to marine propulsion components cannot be avoided completely (Ref 3). Expensive repairs of the strongly damaged areas are mandatory. These are usually realized by build-up welding and subsequent grinding work (Ref [1, 4])
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