Low-pressure cold metal spray coatings for repair and protection of marine components
Description
The marine environment is hostile to most engineering materials, a combination of in-service wear and exposure to marine environment leads to an accelerated material degradation. Insufficient or poor protection of the substrates further assists the accelerated material degradation in marine environment.
There is a direct relationship between the material-state of a ship and its operational capability, readiness, and service life. The current state-of-the-art practice is to use paint-based coatings to maintain the material-state of ships. However, the protection offered by paint coatings is usually brief due to inherent permeability and low damage tolerance of these coatings. For this reason, the paint coatings require renewal at regular intervals, typically less than 5-years, to maintain a minimum level of protection from the marine environment. The need for regular painting of ships results in a significant negative impact on the through-life availability, operational capability/readiness, and the cost of maintenance/operation of naval ships. Therefore, the fleet owners and operators should look beyond the conventional paint-based coatings to achieve significant breakthrough improvements in maintaining and enhancing the material-state of naval ships.
Metallic coatings, if selected and applied appropriately, will outperform the paint coatings in the marine environment. Historically, the cost and performance of metallic coatings, mainly thermal metal spray (TMS) coatings, prevented their widespread use in the marine industry. The TMS coatings also have their own inherent application and performance related limitations that are widely reported in the literature. However, the cold metal spray (CMS) coating process can overcome the application and performance related limitations that are typically associated with the TMS coatings, therefore creating an opportunity for widespread use of metallic coatings in shipbuilding and fleet upkeep/maintenance.
In this paper, the ability of low-pressure (LP-CMS) coatings to repair and reclaim damaged marine components, and application of functional coatings to improve in-service damage tolerance of the damaged/new components is investigated. The results of the investigation show that two LP-CMS coatings, Al-alloy and CuZn-alloy, can be used to repair and preserve both new and damaged components. The accelerated salt-spray and natural immersion corrosion testing of the LP-CMS coatings showed that each coating will be better suited to a particular operational environment, i.e. CuZn-alloy coating performed well in both immersion and atmospheric corrosion environments, whereas Al-alloy coating performed well only in atmospheric corrosion environment.
Files
Restricted
The record is publicly accessible, but files are restricted to users with access.
Request access
If you would like to request access to these files, please fill out the form below.
You need to satisfy these conditions in order for this request to be accepted:
Copyright ©2018 BAE Systems; All Rights Reserved. BAE SYSTEMS is a registered trademark of BAE Systems plc.
This publication is issued to provide outline information only. No advice given or statements or recommendations made shall in any circumstances constitute or be deemed to constitute a warranty or representation by BAE Systems as to the accuracy or completeness of such advice, statements or recommendations. BAE Systems shall not be liable for any loss, expense, damage or claim howsoever arising out of the advice given or not given or statements made or omitted to be made in connection with this document. No part of this document may be copied, reproduced, adapted or redistributed in any form or by any means without the express prior written consent of BAE Systems.
You are currently not logged in. Do you have an account? Log in here
Additional details
References
- Defence Select Committee, 3rd Report - Restoring the Fleet: Naval Procurement and the National Shipbuilding Strategy, Appendix 1: Numbers of ships in the surface fleet, November 21 2016.
- Defence Select Committee, 3rd Report - Restoring the Fleet: Naval Procurement and the National Shipbuilding Strategy, Appendix 1: Numbers of ships in the surface fleet, November 21 2016.
- Ford, G., McMahon, C., and Rowley, C.: "An examination of significant issues in naval maintenance", The Fourth International Conference on Through-life Engineering Services, Procedia CIRP 38, pp 197-203, 2015.
- Herzberg, E., Chan, T., Guo, S., Morris, A., Stevenson, A., and Stroh, R.: "Estimated impact of corrosion on cost and availability of DoD weapon systems", March 2018.
- Kawaguchi, Y., Miyazaki, F., Yamasaki, M., Yamagata, Y., Kobayashi, N., and Muraoka, K.: "Coating qualities deposited using three different thermal spray technologies in relation with temperatures and velocities of spray droplets", Coatings, 7, 27, 2017.
- Kim, G., Champagne, V., Trexler, M., and Sohn, Y.: "Processing nanostructured metal and metal-matrix coatings by thermal and cold spraying", Nanostructured Metals and Alloys, Woodhead Publishing, pages 615662, 2011.
- Little, B., and Lee, J.: "Microbiologically influenced corrosion", Wiley, ISBN – 978-0-471-77276-7, 2007.
- Lyon, S., Bingham, R., and Mills, D.: "Advances in corrosion protection by organic coatings – what we know and what we would like to know", Progress in Organic Coatings, Vol. 102, Part-A, pages 2-7, 2017.
- Ming Ang, A., Noppakun, S., Sesso, M., and Berndt, C.: "Thermal spray maps: material genomics of processing technologies", Journal of Thermal Spray Technology, Vol. 22, pages 1170-1184, 2013.
- Papyrin, A.: "Chapter 2 - The development of the cold spray process", Editor(s): Victor K. Champagne, In Woodhead Publishing Series in Metals and Surface Engineering, The Cold Spray Materials Deposition Process, Woodhead Publishing, Pages 11-42, 2007.
- Revie, R., and Uhlig, H.: "Corrosion and corrosion control – an introduction to corrosion science and engineering", 4th Edition, John Wiley & Sons, ISBN 978-0-471-73279-2, 2008.
- Sumon, T., Lyon, S., and Scntlebury, J.: "Failure of aluminium metal spray/organic duplex coating systems on structural steel", Corrosion Engineering, Science and Technology, Vol. 48, No. 7, pages 552-557, 2013.
- Webb, G.: "Twisted rudder design for reduced rudder cavitation", Transactions of RINA, International Journal of Maritime Engineering, 2017.
- Wood, R.: "Erosion-corrosion interactions and their effect on marine and offshore materials", Wear, Vol. 261, pages 1012-1023, 2006.
- Yang, K., Li, W., Yang, X., and Xu, Y.: "Anisotropic response of cold sprayed copper deposits", Surface and Coatings Technology, Vol. 335, pages 219-227, 2018. Conference