Advertisement

Journal of Thermal Spray Technology

, Volume 28, Issue 5, pp 1060–1071 | Cite as

A Comparative Study of Cavitation Erosion Resistance of Several HVOF-Sprayed Coatings in Deionized Water and Artificial Seawater

  • Haijun Zhang
  • Yongfeng Gong
  • Xiuyong ChenEmail author
  • André McDonald
  • Hua LiEmail author
Peer Reviewed
  • 52 Downloads

Abstract

In this study, WC-10Co4Cr coatings, Co-based coatings, WC-10Co4Cr/Co-based composite coatings, and Fe-based amorphous/nanocrystalline coatings were prepared on 316L stainless steel substrates by a high-velocity oxy-fuel spraying process. The cavitation erosion resistances of all the coatings, as well as the stainless steel substrates, were investigated in deionized water and artificial seawater. Results show that the effect of marine corrosion on cavitation erosion was most significant on the stainless steels, WC-10Co4Cr coatings, and Co-based coatings, but negligible on the WC-10Co4Cr/Co-based composite coatings and the Fe-based amorphous/nanocrystalline coatings. The WC-10Co4Cr coatings (0.17 mm3/h) show improved cavitation erosion resistance than those of WC-10Co4Cr/Co-based composite coatings (0.21 mm3/h), 316L stainless steel substrates (0.22 mm3/h), Co-based coatings (0.30 mm3/h), and Fe-based coatings (0.47 mm3/h) in marine environments.

Keywords

cavitation erosion coatings HVOF marine corrosion 

Notes

Acknowledgments

This work was supported by China Scholarship Council (No. 201804910094), CAS-Iranian Vice Presidency for Science and Technology Joint Research Project (Grant # 174433KYSB20160085), National Natural Science Foundation of China (Grants # 41706076, 31500772 and 21705158), Key Research and Development Program of Zhejiang Province (Grant # 2017C01003), International Scientific and Technological Cooperation Project of Ningbo (Grant # 2017D10011), and a Natural Sciences and Engineering Research Council of Canada Discovery Grant (Grant # NSERC RGPIN-2018-04298).

References

  1. 1.
    X. Ding, X.D. Cheng, C.Q. Yuan, J. Shi, and Z.X. Ding, Structure of Micro-nano WC-10Co4Cr Coating and Cavitation Erosion Resistance in NaCl Solution, Chin. J. Mech. Eng., 2017, 30(5), p 1239-1247CrossRefGoogle Scholar
  2. 2.
    Z. Shi, J. Wang, Z. Wang, Y.T. Xiong, and Y. Zheng, Cavitation Erosion and Jet Impingement Erosion Behavior of the NiTi Coating Produced by Air Plasma Spraying, Coatings, 2018, 8(10), p 346CrossRefGoogle Scholar
  3. 3.
    S. Zhang, S. Wang, C.L. Wu, C.H. Zhang, M. Guan, and J.Z. Tan, Cavitation Erosion and Erosion-corrosion Resistance of Austenitic Stainless Steel by Plasma Transferred Arc Welding, Eng. Fail. Anal., 2017, 76, p 115-124CrossRefGoogle Scholar
  4. 4.
    Q. Wang, S. Bai, and Z.D. Liu, Study on Cavitation Erosion-Corrosion Behavior of Mild Steel Under Synergistic Vibration Generated by Ultrasonic Excitation, Tri. Trans., 2014, 57, p 603-612CrossRefGoogle Scholar
  5. 5.
    G. Hou, X. Zhao, H. Zhou, J. Lu, Y. An, J. Chen, and J. Yang, Cavitation Erosion of Several Oxy-fuel Sprayed Coatings Tested in Deionized Water and Artificial Seawater, Wear, 2014, 311(1-2), p 81-92CrossRefGoogle Scholar
  6. 6.
    J. Lin, Z. Wang, P. Lin, J. Cheng, X. Zhang, and S. Hong, Microstructure and Cavitation Erosion Behavior of FeNiCrBSiNbW Coating Prepared by Twin Wires Arc Spraying Process, Surf. Coat. Technol., 2014, 240, p 432-436CrossRefGoogle Scholar
  7. 7.
    W. Deng, Y. An, G. Hou, S. Li, H. Zhou, and J. Chen, Effect of Substrate Preheating Treatment on the Microstructure and Ultrasonic Cavitation Erosion Behavior of Plasma-Sprayed YSZ Coatings, Ultrason. Sonochem., 2018, 46, p 1-9CrossRefGoogle Scholar
  8. 8.
    C.L. Wu, S. Zhang, C.H. Zhang, H. Zhang, and S.Y. Dong, Phase Evolution and Cavitation Erosion-corrosion Behavior of FeCoCrAlNiTix High Entropy Alloy Coatings on 304 Stainless Steel by Laser Surface Alloying, J. Alloys Compd., 2017, 698, p 761-770CrossRefGoogle Scholar
  9. 9.
    S. Zhang, C.L. Wu, C.H. Zhang, M. Guan, and J.Z. Tan, Laser Surface Alloying of FeCoCrAlNi High-Entropy Alloy on 304 Stainless Steel to Enhance Corrosion and Cavitation Erosion Resistance, Opt. Laser Technol., 2016, 84, p 23-31CrossRefGoogle Scholar
  10. 10.
    C.T. Kwok, H.C. Man, F.T. Cheng, and K.H. Lo, Developments in Laser-based Surface Engineering Processes: With Particular Reference to Protection Against Cavitation Erosion, Surf. Coat. Technol., 2016, 291, p 189-204CrossRefGoogle Scholar
  11. 11.
    S. Hong, Y. Wu, J. Zhang, Y. Zheng, Y. Qin, and J. Lin, Ultrasonic Cavitation Erosion of High-Velocity Oxygen-Fuel (HVOF) Sprayed Near-Nanostructured WC-10Co-4Cr Coating in NaCl Solution, Ultrason. Sonochem., 2015, 26, p 87-92CrossRefGoogle Scholar
  12. 12.
    G. Hou, Y. An, X. Zhao, H. Zhou, and J. Chen, Effect of Alumina Dispersion on Oxidation Behavior as well as Friction and Wear Behavior of HVOF-Sprayed CoCrAlYTaCSi Coating at Elevated Temperature Up to 1000 °C, Acta Mater., 2015, 95, p 164-175CrossRefGoogle Scholar
  13. 13.
    D. Niebuhr, Cavitation Erosion Behavior of Ceramics in Aqueous Solutions, Wear, 2007, 263(1-6), p 295-300CrossRefGoogle Scholar
  14. 14.
    G. Taillon, F. Pougoum, S. Lavigne, L. Ton-That, R. Schulz, E. Bousser, S. Savoie, L. Martinu, and J.-E. Klemberg-Sapieha, Cavitation Erosion Mechanisms in Stainless Steels and in Composite Metal-Ceramic HVOF Coatings, Wear, 2016, 364, p 201-210CrossRefGoogle Scholar
  15. 15.
    A. Furusawa, K. Hine, Y. Hayashi, and H. Takizawa, Formation of Particle of Bismuth-indium Alloys and Particle Diameter by Ultrasonic Cavitation, Ultrason. Sonochem., 2019, 50, p 322-330CrossRefGoogle Scholar
  16. 16.
    R. Zhang, Y. Ren, D. Yan, P. Guo, and L. Li, Synthesis of Hydrophobic Fluorinated Polyurethanes and Their properties of Resistance to Cavitation and Wear, Prog. Org. Coat., 2017, 104, p 11-19CrossRefGoogle Scholar
  17. 17.
    S. Lavigne, F. Pougoum, S. Savoie, L. Martinu, J.E. Klemberg-Sapieha, and R. Schulz, Cavitation Erosion Behavior of HVOF CaviTec Coatings, Wear, 2017, 386-387, p 90-98CrossRefGoogle Scholar
  18. 18.
    C.R. Ciubotariu, E. Secosan, G. Marginean, D. Frunzaverde, and V.C. Campian, Experimental Study Regarding the Cavitation and Corrosion Resistance of Stellite 6 and Self-fluxing Remelted Coatings, J. Mech. Eng., 2016, 62(3), p 154-162CrossRefGoogle Scholar
  19. 19.
    Z. Wang, X. Zhang, J. Cheng, J. Lin, and Z. Zhou, Cavitation Erosion Resistance of Fe-Based Amorphous/Nanocrystal Coatings Prepared by High-Velocity Arc Spraying, J. Therm. Spray Technol., 2014, 23(4), p 742-749CrossRefGoogle Scholar
  20. 20.
    S. Hong, Y. Wu, J. Zhang, Y. Zheng, Y. Qin, and J. Lin, Effect of Ultrasonic Cavitation Erosion on Corrosion Behavior of High-Velocity Oxygen-Fuel (HVOF) Sprayed Near-Nanostructured WC-10Co-4Cr Coating, Ultrason. Sonochem., 2015, 27, p 374-378CrossRefGoogle Scholar
  21. 21.
    K.R. Kumar, M. Kamaraj, S. Seetharamu, and S.A. Kumar, A Pragmatic Approach and Quantitative Assessment of Silt Erosion Characteristics of HVOF and HVAF Processed WC-CoCr Coatings and 16Cr5Ni Steel for Hydro Turbine Applications, Mater. Des., 2017, 132, p 79-95CrossRefGoogle Scholar
  22. 22.
    R.K. Kumar, M. Kamaraj, S. Seetharamu, T. Pramod, and P. Sampathkumaran, Effect of Spray Particle Velocity on Cavitation Erosion Resistance Characteristics of HVOF and HVAF Processed 86WC-10Co4Cr Hydro Turbine Coatings, J. Therm. Spray Technol., 2016, 25(6), p 1217-1230CrossRefGoogle Scholar
  23. 23.
    A. Neville, F. Reza, S. Chiovelli, and T. Revega, Assessing Metal Matrix Composites for Corrosion and Erosion-corrosion Applications in the Oils Sands Industry, Corrosion, 2006, 62, p 657-675CrossRefGoogle Scholar
  24. 24.
    N. Melendez and A. McDonald, Development of WC-Based Metal Matrix Composite Coatings Using Low-pressure Cold Gas Dynamic Spraying, Surf. Coat. Technol., 2013, 214, p 101-109CrossRefGoogle Scholar
  25. 25.
    N. Melendez, V. Narulkar, G. Fisher, and A. McDonald, The Effect of Reinforcing Particles on the Wear Rate of Low-Pressure Cold-Sprayed WC-Based MMC Coatings, Wear, 2013, 306, p 185-195CrossRefGoogle Scholar
  26. 26.
    S. Hong, Y. Wu, J. Zhang, Y. Zheng, Y. Zheng, and J. Lin, Synergistic Effect of Ultrasonic Cavitation Erosion and Corrosion of WC-CoCr and FeCrSiBMn Coatings Prepared by HVOF Spraying, Ultrason. Sonochem., 2016, 31, p 563-569CrossRefGoogle Scholar
  27. 27.
    “Standard Practice for the Preparation of Substitute Ocean Water,” D1141-98, ASTM, 2003Google Scholar
  28. 28.
    “Standard Test Method for Cavitation Erosion Using Vibratory Apparatus,” G32-16, ASTM, 2016Google Scholar
  29. 29.
    D.A. Stewart, P.H. Shipway, and D.G. McCartney, Microstructural Evolution in Thermally Sprayed WC-Co Coatings: Comparison Between Nanocomposite and Conventional Starting Powders, Acta Mater., 2000, 48(7), p 1593-1604CrossRefGoogle Scholar
  30. 30.
    D. Li, X. Chen, X. Hui, J. Wang, P. Jin, and H. Li, Effect of Amorphicity of HVOF Sprayed Fe-Based Coatings on Their Corrosion Performances and Contacting Osteoblast Behavior, Surf. Coat. Technol., 2017, 310, p 207-213CrossRefGoogle Scholar
  31. 31.
    H. Zhang, Y. Gong, B. Zhang, X. Chen, L. Fang, P. Jin, and H. Li, Corrosion and Algal Adhesion Behaviors of HVOF-Sprayed Fe-Based Amorphous Coatings for Marine Applications, J. Therm. Spray Technol., 2019, 28(1-2), p 283-290CrossRefGoogle Scholar
  32. 32.
    W. Deng, G. Hou, S. Li, J. Han, X. Zhao, X. Liu, Y. An, H. Zhou, and J. Chen, A New Methodology to Prepare Ceramic-Organic Composite Coatings with Good Cavitation Erosion Resistance, Ultrason. Sonochem., 2018, 44, p 115-119CrossRefGoogle Scholar
  33. 33.
    A. Krella and A. Czyzniewski, Influence of the Substrate Hardness on the Cavitation Erosion Resistance of TiN Coating, Wear, 2007, 263(1-6), p 395-401CrossRefGoogle Scholar
  34. 34.
    L. Qiao, Y. Wu, S. Hong, J. Zhang, W. Shi, and Y. Zheng, Relationships Between Spray Parameters, Microstructures and Ultrasonic Cavitation Erosion Behavior of HVOF Sprayed Fe-based Amorphous/Nanocrystalline Coatings, Ultrason. Sonochem., 2017, 39, p 39-46CrossRefGoogle Scholar
  35. 35.
    A. Ayyagari, V. Hasannaeimi, H.S. Grewal, H. Arora, and S. Mukherjee, Corrosion, Erosion and Wear Behavior of Complex Concentrated Alloys: A Review, Metals, 2018, 8(8), p 603CrossRefGoogle Scholar
  36. 36.
    H. Liu, T. Zhang, and C. Kang, Evaluation of Cavitation Erosion Resistance of Copper Alloy in Different Liquid Media, Mater. Corros., 2018, 69, p 917-925CrossRefGoogle Scholar
  37. 37.
    Q. Luo, Q. Zhang, Z. Qin, Z. Wu, B. Shen, L. Liu, and W. Hu, The Synergistic Effect of Cavitation Erosion and Corrosion of Nickel-aluminum Copper Surface Layer on Nickel-aluminum Bronze Alloy, J. Alloys Compd., 2018, 747, p 861-868CrossRefGoogle Scholar
  38. 38.
    M.A. Islam and Z. Farhat, Erosion-corrosion Mechanism and Comparison of Erosion-Corrosion Performance of API, Steels, Wear, 2017, 376-377, p 533-541CrossRefGoogle Scholar
  39. 39.
    J. Ryl, J. Wysocka, P. Slepski, and K. Darowicki, Instantaneous Impedance Monitoring of Synergistic Effect Between Cavitation Erosion and Corrosion Processes, Electrochim. Acta, 2016, 203, p 388-395CrossRefGoogle Scholar
  40. 40.
    E. Sadeghimeresht, N. Markocsan, and P. Nylén, A Comparative Study of Corrosion Resistance for HVAF-Sprayed Fe- and Co-Based Coatings, Coatings, 2016, 6(2), p 16CrossRefGoogle Scholar
  41. 41.
    M.M. Lima, C. Godoy, P.J. Modenesi, J.C. Avelar-Batista, A. Davison, and A. Matthews, Coating Fracture Toughness Determined by Vickers Indentation: An Important Parameter in Cavitation Erosion Resistance of WC-Co Thermally Sprayed Coatings, Surf. Coat. Technol., 2004, 177-178, p 489-496CrossRefGoogle Scholar
  42. 42.
    L.A. Espitia and A. Toro, Cavitation Resistance, Microstructure and Surface Topography of Materials Used for Hydraulic Components, Tribol. Int., 2010, 43, p 2037-2045CrossRefGoogle Scholar

Copyright information

© ASM International 2019

Authors and Affiliations

  1. 1.Key Laboratory of Marine Materials and Related Technologies, Zhejiang Key Laboratory of Marine Materials and Protective Technologies, Ningbo Institute of Materials Technology and EngineeringChinese Academy of SciencesNingboChina
  2. 2.Cixi Institute of Biomedical Engineering, Ningbo Institute of Materials Technology and EngineeringChinese Academy of SciencesNingboChina
  3. 3.Department of Mechanical EngineeringUniversity of AlbertaEdmontonCanada

Personalised recommendations