Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze
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Study of Traverse Speed Effects on Residual Stress State and Cavitation Erosion Behavior of Arc-Sprayed Aluminum Bronze Coatings Miche´l Hauer1 • Knuth Michael Henkel1 • Sebastian Krebs2 • Werner Kroemmer3
Submitted: 30 May 2016 / in revised form: 26 July 2016 / Published online: 8 December 2016 ASM International 2016
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
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. & Miche´l Hauer [email protected] 1
Fraunhofer Application Center Large Structures in Production Engineering, Albert-Einstein-Str. 30, Rostock 18059, Germany
2
Helmut-Schmidt University, University of the Federal Armed Forces Hamburg, Holstenhofweg 85, Hamburg 22043, Germany
3
Linde AG, Linde Gases Division, Carl-von-Linde-Straße 25, Unterschleissheim 85716, Germany
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. Keywords aluminum bronze cavitation-resistant coatings electronic speckle pattern interferometry hole drilling method marine components residual stress wire arc spray
Introduction Severe erosion on modern containerships, ferries and other ships traveling with higher speeds endangers ship operation, as shown in Fig. 1. Saltwater environment and dispersed sediments can lead to high corrosion rates and abrasive wear. Besides, cavitation erosion is one main factor (Ref 1). It is defined as the material loss caused by the formation and collapse of vapor bubbles due to pressure oscillations (Ref 2). Du
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