Effect of Microstructure and Hardness on Cavitation Erosion and Dry Sliding Wear of HVOF Deposited CoNiCrAlY, NiCoCrAlY and NiCrMoNbTa Coatings

Metallic coatings based on cobalt and nickel are promising for elongating the life span of machine components operated in harsh environments. However, reports regarding the ambient temperature tribological performance and cavitation erosion resistance of popular MCrAlY (where M = Co, Ni or Co/Ni) and NiCrMoNbTa coatings are scant. This study comparatively investigates the effects of microstructure and hardness of HVOF deposited CoNiCrAlY, NiCoCrAlY and NiCrMoNbTa coatings on tribological and cavitation erosion performance. The cavitation erosion test was conducted using the vibratory method following the ASTM G32 standard. The tribological examination was done using a ball-on-disc tribometer. Analysis of the chemical composition, microstructure, phase composition and hardness reveal the dry sliding wear and cavitation erosion mechanisms. Coatings present increasing resistance to both sliding wear and cavitation erosion in the following order: NiCoCrAlY < CoNiCrAlY < NiCrMoNbTa. The tribological behaviour of coatings relies on abrasive grooving and oxidation of the wear products. In the case of NiCrMoNbTa coatings, abrasion is followed by the severe adhesive smearing of oxidised wear products which end in the lowest coefficient of friction and wear rate. Cavitation erosion is initiated at microstructure discontinuities and ends with severe surface pitting. CoNiCrAlY and NiCoCrAlY coatings present semi brittle behavior, whereas NiCrMoNbTa presents ductile mode and lesser surface pitting, which improves its anti-cavitation performance. The differences in microstructure of investigated coatings affect the wear and cavitation erosion performance more than the hardness itself.

Cavitation erosion behavior of hydraulic concrete under high-speed flow

Purpose Cavitation erosion has always been a common technical problem in a hydraulic discharging structure. This paper aims to investigate the cavitation erosion behavior of hydraulic concrete under high-speed flow. Design/methodology/approach A high-speed and high-pressure venturi cavitation erosion generator was used to simulate the strong cavitation. The characteristics of hydrodynamic loads of cavitation bubble collapse zone, the failure characteristics and the erosion development process of concrete were investigated. The main influencing factors of cavitation erosion were discussed. Findings The collapse of the cavitation bubble group produced a high frequency, continuous and unsteady pulse load on the wall of concrete, which was more likely to cause fatigue failure of concrete materials. The cavitation action position and the main frequency of impact load were greatly affected by the downstream pressure. A power exponential relationship between cavitation load, cavitation erosion and flow speed was observed. With the increase of concrete strength, the degree of damage of cavitation erosion was approximately linearly reduced. Originality/value After cavitation erosion, a skeleton structure was formed by the accumulation of granular particles, and the relatively independent bulk structure of the surface differed from the flake structure formed after abrasion.

Assessment of Cavitation Erosion in a Water-Jet Pump Based on the Erosive Power Method

Cavitation affects the performance of water-jet pumps. Cavitation erosion will appear on the surface of the blade under long-duration cavitation conditions. The cavitation evolution under specific working conditions was simulated and analyzed. The erosive power method based on the theory of macroscopic cavitation was used to predict cavitation erosion. The result shows that the head of the water-jet pump calculated using the DCM-SST turbulence model is 12.48 m. The simulation error of the rated head is 3.8%. The cavitation structure of tip leakage vortex was better captured. With the decrease of the net positive suction head, the position where the severe cavitation appears in the impeller domain gradually moves from the tip to the root. The erosion region obtained by the cavitation simulation based on the erosive power method is similar to the practical erosion profile in engineering. As the net positive suction head decreases, the erodible area becomes larger, and the erosion intensity increases.

Recent Progresses in Super-Hydrophobicity and Micro-Texturing for Engineering Applications

Increasing interests have been prevalent lately among the research fraternity for the development of superhydrophobic surfaces considering the favorable properties exuded by them. Recently, anti-microbial superhydrophobic coatings have been employed effectively in anti-biofouling, corrosion resistance, and self-cleaning, anti-reflecting coating, biomedical and cavitation erosion applications. Further, patterned topology by micro/nano surface texturing has been perceived as an engineering opportunity to enhance the surface performance and has opened various avenues for exploration. This work reports the recent research findings pertaining to the concept of superhydrophobicity and micro-texturing particularly in the context of their application for the impediment of corrosion in submerged components. The comprehensive review on superhydrophobic surfaces and micro-texturing suggests that the integrated application of these surface modification techniques for mechanical interlocking of deposited coating.

Numerical Simulation of Random Cavitation Suppression Based on Variable NACA Airfoils

In order to suppress the cavitation of an airfoil under random operating conditions, a deformable covering was constructed in the cavitation prone area of the NACA0012 airfoil. By sensing the pressure difference between the inner and outer sides of the airfoil, the covering of the airfoil can be changed adaptively to meet the requirement of suppressing random cavitation of the airfoil. The simulation results show that the cavitation influence range of the airfoil with a shape memory alloy covering can be reduced by more than 70%, and the cavitation is well reduced and suppressed. Moreover, the backflow near the wall of the airfoil was reduced under random working conditions. When the maximum bulge deformation of the covering was between 3–6 mm, the airfoil produced a cavitation range only on the covering surface of the airfoil, and there was no cavitation erosion on other parts. This method with locally variable airfoil to suppress cavitation provides a good reference value for other hydraulic machinery to suppress cavitation.

Cavitation erosion damage of self-fluxing NiCrSiB hardfacings deposited by oxy-acetylene powder welding

This paper comparatively investigates the cavitation erosion damage of two self-fluxing NiCrSiB hardfacings deposited via the oxy-acetylene powder welding method. Examinations were conducted according to the procedure given by ASTM G32 standard. In order to research cavitation erosion (CE), the vibratory apparatus was employed. The cavitation damaged surfaces were inspected using a scanning electron microscope, optical microscope and surface profilometer. The hardness of the A-NiCrSiB hardfacing equals 908HV while that of C-NiCrSiB amounts to 399HV. The research showed that the CE resistance of C-NiCrSiB is higher than that of A-NiCrSiB. The results demonstrate that in the case of multiphase materials, like the NiCrSiB hardfacings, hardness cannot be the key factor for cavitation erosion damage estimation whereas it is strongly subjected to material microstructure. In order to qualitatively recognise the cavitation erosion damage of the NiCrSiB self-fluxing hardfacings at a given exposure time, the following factors should be respected: physical and mechanical properties, material microstructure and also material loss and eroded surface morphology, both stated at specific testing time. The general idea for the cavitation erosion damage estimation of the NiCrSiB oxy-acetylene welds was presented.