Automated Complex for the Reclamation and Anti-Corrosion Protection of Steel Marine Propellers via Supersonic Cold Gas-Dynamic Spraying Utilizing AI-Driven Control

This paper presents the technological concept and architecture of a robotic manufacturing system (RMS) designed for the precision reclamation and long-term anti-corrosion protection of steel marine propellers utilized in sea-going and river vessels. The proposed method integrates cold gas-dynamic spraying (CGDS) technology with a 6-axis industrial manipulator equipped with an artificial intelligence (AI)-based computer vision system and an automatic tool changer (ATC). This technology mitigates the issues of cavitational and electrochemical degradation of propeller blades by introducing an adaptive manufacturing cycle. This cycle encompasses contactless 3D defect mapping, abrasive preparation, supersonic spraying of functional coatings, and force-controlled (Force-Torque) adaptive finish grinding. This comprehensive approach eliminates thermal distortion of the treated component, minimizes hydrodynamic drag, and extends the operational lifespan of the protective coating by a factor of 4–5 compared to conventional techniques. Furthermore, the economic viability of implementing this technology is evaluated, with a specific focus on the on-site repair of ultra-large vessels (supertankers) without the need for propeller disassembly.
Keywords: Cold gas-dynamic spraying, robot manipulator, artificial intelligence, computer vision, marine propeller, cavitation erosion, adaptive grinding, supertankers.