Study on anti-wear protection technology of water pump

**Abstract**: Cavitation, erosion, and joint damage in pumps have long been critical challenges in the operation, maintenance, and management of water pump systems. Traditional surface protection materials and methods are no longer sufficient to meet the growing demands for anti-cavitation and anti-erosion performance. To improve the resistance of pump components against cavitation and abrasion, various surface protection technologies have been explored and developed beyond the use of stainless steel or cemented carbides for blades and impellers. This article provides an overview of recent advancements in this field. **Keywords**: Pump anti-wear protection; Surface coating technology; Cavitation resistance; Erosion protection Cavitation, erosion, and joint damage have always posed significant challenges in the operation and maintenance of pumps. The conventional surface protection materials and techniques often fall short in providing adequate resistance to these damaging effects. To address this, researchers and engineers have continuously explored new surface protection methods. This paper outlines the current status and recent developments in this area. **1. Research Status of Surface Protection Technology** **1.1 Non-Metallic Coating Development** In the 1960s and 1970s, China began using epoxy resins and their compounds for anti-abrasion protection in pumps. By the 1980s, composite coatings, polyurethane, ceramic-like coatings, and rubber-based coatings were also introduced. Other non-metallic coatings, such as those made from quick-setting titanium rubber, enamel, ceramics, and glass, were developed but saw limited use due to complex manufacturing processes. In the 1990s, the U.S. introduced materials like DEVCON agents, ARC composites, and synthetic rubbers. However, these non-metallic coatings often failed in harsh pumping environments due to weak adhesion to metal substrates and insufficient hardness, resulting in poor performance against cavitation and erosion. **1.2 Metal Coating Research** Metal-based surface protection has also been widely applied. Electrode surfacing and wire spraying are among the most common methods. While electrode surfacing offers strong bonding, it can lead to uneven thickness and high heat input, which may damage the substrate. Wire-sprayed stainless steel coatings, though easier to apply, are mechanically bonded and not suitable for high-impact conditions. For large pumps, such as axial-flow impellers with diameters over three meters, stainless steel plates can be embedded on the surface, but this method requires specialized equipment and is costly and time-consuming. Alloy powder coatings, developed from wire spraying, offer better control over thickness and smoother surfaces. However, they are typically used for less severe applications due to internal stresses from the layer-by-layer deposition process. **1.3 Technical Requirements for Surface Protective Materials** Effective anti-wear coatings must meet several criteria: (1) high strength and hardness to resist cavitation and erosion, (2) good toughness to absorb impact energy, (3) strong adhesion to prevent spalling under high-speed flow (up to 30–35 m/s), (4) cost-effective for widespread application in both large and small pumping stations, and (5) safe and environmentally friendly, with no toxic or flammable properties. **1.4 Processing Requirements** To ensure practical application, the processing technology must be simple, accessible, and adaptable. It should not require expensive or specialized equipment, be unaffected by weather or environment, and allow for quick curing or immediate use after application. **2. Advances in Alloy Powder Spray Welding Technology** Spray welding is a metal surface protection technique that combines spraying and welding, using low-melting-point alloy powders. After remelting, the coating becomes dense, smooth, and free of pores, offering excellent material efficiency, quality, and productivity. The surface hardness of spray-welded coatings can reach HRC 60–70, significantly extending the life of pump components. **2.1 Optimization of Spray-Welding Alloy Powders** To enhance coating quality and prevent defects, researchers have focused on optimizing material composition and process parameters. This includes adjusting the particle size and distribution of hardened phases, tailoring material properties to match pump-specific cavitation and erosion conditions, and ensuring strong adhesion and improved weldability. These improvements help reduce crack formation and increase the overall durability of the coated surfaces.

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