Journal of Thermal Spray Technology

, Volume 26, Issue 1–2, pp 265–277 | Cite as

Warm Spraying of High-Strength Ni-Al-Bronze: Cavitation Characteristics and Property Prediction

  • Sebastian Krebs
  • Seiji Kuroda
  • Hiroshi Katanoda
  • Frank Gaertner
  • Thomas Klassen
  • Hiroshi Araki
  • Simon Frede
Peer Reviewed
First Online:
Received:
Revised:

Abstract

Bronze materials such as Ni-Al-bronze show exceptional performances against cavitation erosion, due to their high fatigue strength and high strength. These materials are used for ship propellers, pump systems or for applications with alternating stresses. Usually, the respective parts are cast. With the aim to use resources more efficiently and to reduce costs, this study aimed to evaluate opportunities to apply bronze as a coating to critical areas of respective parts. The coatings should have least amounts of pores and non-bonded areas and any contaminations that might act as crack nuclei and contribute to material damages. Processes with low oxidation and high kinetic impacts fulfill these criteria. Especially warm spraying, a nitrogen-cooled HVOF process, with similar impact velocities as cold gas spraying but enhanced process temperature, allows for depositing high-strength Ni-Al-bronze. This study systematically simulates and evaluates the formation and performance of warm-sprayed Ni-Al-bronze coatings for different combustion pressures and nitrogen flow rates. Substrate preheating was used to improve coating adhesion for lower spray parameter sets. Furthermore, this study introduces an energy-based concept to compare spray parameter sets and to predict coating properties. Coatings with low porosities and high mechanical strengths are obtained, allowing for a cavitation resistance similar to bulk material.

Keywords

bronze-coatings cavitation erosion marine components protective coatings simulation warm spraying 
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Notes

Acknowledgments

The authors would like to thank (in alphabetical order) T. Breckwoldt, T. Hiraoka, N. Németh, C. Schulze, M. Schulze and U. Wagener, for their support in experiments and specimen characterization and Prof. Hamid. Assadi and M. Villa for their fruitful discussions. The research Project (No. 18449 BG/1) of the research community Center of Maritime Technologies (CMT), Bramfelder Straße 164, 22305 Hamburg, has been funded by the AiF within the program for sponsorship by Industrial Joint Research (IGF) of the German Federal Ministry of Economic Affairs and Energy based on an enactment of the German parliament. This support is greatly acknowledged.

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Copyright information

© ASM International 2016

Authors and Affiliations

  • Sebastian Krebs
    • 1
  • Seiji Kuroda
    • 2
  • Hiroshi Katanoda
    • 3
  • Frank Gaertner
    • 1
  • Thomas Klassen
    • 1
  • Hiroshi Araki
    • 2
  • Simon Frede
    • 1
  1. 1.Department of Mechanical EngineeringHelmut Schmidt University/University of the Federal Armed Forces HamburgHamburgGermany
  2. 2.High Temperature Materials UnitNational Institute for Materials ScienceTsukubaJapan
  3. 3.Kagoshima UniversityKagoshimaJapan

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