**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 to cavitation and wear, in addition to using stainless steel or other hard alloys for blades and impellers, various surface protection technologies have been continuously explored and developed. This article outlines recent advancements in this field.
**Keywords:** Water pump; anti-wear protection; cavitation; erosion; surface protection technology
Cavitation and erosion, along with their combined effects, have long posed significant challenges in pump operation and maintenance. Conventional surface protection materials and techniques are often inadequate in providing effective resistance against these damaging forces. To enhance the durability of pump components, especially those exposed to high-speed fluid flow, researchers and engineers have turned to advanced surface protection methods beyond traditional materials like stainless steel and cemented carbides.
One area of development has focused on non-metallic coatings. In the 1960s and 1970s, epoxy resins were first applied to protect pump surfaces from erosion. By the 1980s, more advanced options such as polyurethane, rubber-like coatings, and ceramic-like materials were introduced. Although some of these materials showed promise, their application was limited due to complex manufacturing processes and poor adhesion to metal substrates. In the 1990s, polymer-based materials such as DEVCON and synthetic rubbers were also tested, but they still faced issues with bonding strength and hardness in harsh pumping environments.
Metallic coatings have also been widely used in pump protection. Electrode surfacing and wire spraying are common techniques. While electrode surfacing offers strong bonding, it can lead to uneven layers and high heat input, which may cause distortion. Wire-sprayed coatings, though easier to apply, lack the mechanical strength needed for high-impact and high-cavitation environments. For large pumps, inlaying stainless steel plates is another approach, but it requires specialized equipment and is costly and time-consuming.
To address these limitations, alloy powder spray welding has emerged as a promising technique. It combines the benefits of spraying and welding, producing dense, smooth coatings with high hardness (up to HRC 60–70). This method significantly extends the service life of pump components, making it ideal for both small and large-scale applications.
In terms of material requirements, protective coatings must be strong, tough, and highly bonded to the substrate. They should also be cost-effective, safe, and easy to handle. Processing methods need to be simple, adaptable to different environments, and not dependent on special equipment or conditions. The ability to quickly apply and use the coating without additional thermal treatment is also essential.
Recent developments in alloy powder spray welding have focused on optimizing material composition and process parameters. By adjusting the particle size, distribution, and phase content, researchers have improved the structural integrity and performance of the coatings. These improvements help reduce cracking, enhance wear resistance, and ensure better adhesion under demanding operating conditions.
Overall, the continuous advancement in surface protection technologies is playing a crucial role in improving the reliability and longevity of water pumps, making them more efficient and cost-effective in real-world applications.
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