**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 enhance the durability of pump components exposed to high-speed fluid flow, various surface protection technologies have been explored beyond conventional materials like stainless steel or cemented carbides. This article provides an overview of recent developments in this field.
**Keywords:** Water pump; Anti-wear protection; Cavitation; Erosion; Surface protection technology
The issue of cavitation, erosion, and their combined effects on pump components has long been a major concern in pump operation and maintenance. While traditional protective materials such as stainless steel and cemented carbides are still widely used, they often fall short in providing long-term resistance to these destructive forces. As a result, researchers and engineers have continuously explored new surface protection techniques to improve the longevity and efficiency of pump parts.
One of the early approaches involved the use of non-metallic coatings, such as epoxy resins, polyurethanes, and rubber-like materials. These were introduced in the 1960s and 1970s in China, and later expanded with composite coatings, ceramic-like materials, and synthetic rubbers. However, many of these materials had limitations, including poor adhesion to metal substrates and insufficient hardness, which made them unsuitable for harsh pumping environments.
Metallic coatings, particularly electrode surfacing and wire spraying, have also been extensively studied. Electrode surfacing offers strong bonding between the coating and the base material, but it can lead to uneven thickness and high heat input, which may affect the substrate. Wire-sprayed stainless steel coatings, while easier to apply, are mechanically bonded and not ideal for high-impact or cavitation-prone areas. For large pumps, inlaying stainless steel plates is another option, but this method is costly and time-consuming, making it impractical for smaller facilities.
Alloy powder spray welding has emerged as a promising alternative. It combines the benefits of both spraying and welding, producing dense, smooth coatings with high hardness (up to HRC 60–70). This technique significantly extends the service life of pump components and is more cost-effective than traditional methods.
Recent advancements in alloy powder spray welding have focused on optimizing material composition and process parameters. By adjusting the ratio of hard phases, particle size, and thermal conditions, researchers have improved the mechanical properties of the coatings, reduced crack formation, and enhanced adhesion. These improvements make the technology more suitable for a wide range of pump applications, from small-scale rural systems to large industrial pumping stations.
In addition to material optimization, the processing technology must be simple, cost-effective, and adaptable to different environments. Ideal surface protection solutions should be easy to apply, require minimal specialized equipment, and be unaffected by weather or seasonal changes. They should also allow for quick curing and immediate use after application, reducing downtime during maintenance.
Overall, the development of advanced surface protection technologies represents a significant step forward in improving the reliability and efficiency of water pumps. With ongoing research and innovation, these methods are becoming increasingly viable for real-world applications, helping to reduce maintenance costs and extend the lifespan of critical pump components.
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