Correlation of Residual Stresses and Coating Properties in Arc-Sprayed Coatings on Different Substrates for Maritime Applications

• Published in: Journal of thermal spray technology Vol. 29; no. 6; pp. 1289 - 1299
• Main Authors: Hauer, Michél, Krebs, Sebastian, Kroemmer, Werner, Henkel, Knuth-Michael
• Format: Journal Article
• Language: English
• Published: New York Springer US 01.08.2020
• Subjects: Analytical Chemistry; Characterization and Evaluation of Materials; Chemistry and Materials Science; Corrosion and Coatings; Machines; Manufacturing; Materials Science; Peer Reviewed; Processes; Surfaces and Interfaces; Thin Films; Tribology; aluminum bronze; electronic speckle pattern interferometry; marine components; substrate coating interaction; cavitation-resistant coatings; residual stress determination; wire arc spray
• ISSN: 1059-9630; 1544-1016
• DOI: 10.1007/s11666-020-01020-x

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.