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Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze Coatings

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Abstract

Within a research project regarding cavitation erosion-resistant coatings, arc spraying was used with different traverse speeds to influence heat transfer and the resulting residual stress state. The major reason for this study is the lack of knowledge concerning the influence of residual stress distribution on mechanical properties and coating adhesion, especially with respect to heterogeneous aluminum bronze alloys. The materials used for spray experiments were the highly cavitation erosion-resistant propeller alloys CuAl9Ni5Fe4Mn (Ni-Al-Bronze) and CuMn13Al8Fe3Ni2 (Mn-Al-Bronze). Analyses of cavitation erosion behavior were carried out to evaluate the suitability for use in marine environments. Further microstructural, chemical and mechanical analyses were realized to examine adhesive and cohesive coating properties. Residual stress distribution was measured by modified hole drilling method using electronic speckle pattern interferometry (ESPI). It was found that the highest traverse speed led to higher tensile residual stresses near the surface and less cavitation erosion resistance of the coatings. Moreover, high oxygen affinity of main alloying element aluminum was identified to severely influence the microstructures by the formation of large oxides and hence the coating properties. Overall, Mn-Al-Bronze coatings showed lower residual stresses, a more homogeneous pore and oxide distribution and less material loss by cavitation than Ni-Al-Bronze coatings.

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Acknowledgments

The authors would like to thank all co-workers involved in the study, namely listed in alphabetical order: R. Arndt, A. Herhaus, C.-P. Homburg, D. Krüger, R. Lange, N. Németh, B. Ripsch, A. Schober, M. Schulze, K. Utwich and S. Wachtmann. The research project (No. 18449 BG) 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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Authors and Affiliations

  1. Fraunhofer Application Center Large Structures in Production Engineering, Albert-Einstein-Str. 30, Rostock, 18059, Germany

    Michél Hauer & Knuth Michael Henkel

  2. Helmut-Schmidt University, University of the Federal Armed Forces Hamburg, Holstenhofweg 85, Hamburg, 22043, Germany

    Sebastian Krebs

  3. Linde AG, Linde Gases Division, Carl-von-Linde-Straße 25, Unterschleissheim, 85716, Germany

    Werner Kroemmer

Authors
  1. Michél Hauer
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  2. Knuth Michael Henkel
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  3. Sebastian Krebs
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  4. Werner Kroemmer
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Corresponding author

Correspondence to Michél Hauer.

Additional information

This article is an invited paper selected from presentations at the 2016 International Thermal Spray Conference, held May 10-12, 2016, in Shanghai, People’s Republic of China, and has been expanded from the original presentation.

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Hauer, M., Henkel, K.M., Krebs, S. et al. Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze Coatings. J Therm Spray Tech 26, 217–228 (2017). https://doi.org/10.1007/s11666-016-0446-0

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  • DOI: https://doi.org/10.1007/s11666-016-0446-0

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