Erosion behaviour of cold sprayed stainless-steel coatings for civil infrastructures: an energetic approach

Along with corrosion, erosion is one of the main causes of damage to civil infrastructures. The continuous impact of fine particles carried by the air produces a deterioration in the elements of these structures. When this damage is significant, these elements are replaced by new ones. In this work, the possibility of extending the useful life of these components by spraying coatings on the damaged areas is proposed. In this sense, repair techniques such as cold spray deposition are possibilities for this purpose. Therefore, this study focuses on evaluating the erosion behaviour of stainless-steel coatings deposited on structural steel. In addition, the erosion results have been correlated with the model proposed by Hutchings, and an energetic interpretation of the erosion process through this model has been proposed. To carry out this study, stainless steel coatings have been deposited on carbon steel substrates to improve their resistance to corrosion. Different spraying temperatures, from 800 ºC to 1100 ºC, combined with different pressures of the carrier gas, from 40 to 70 bar, have been analysed. The elastic moduli of the coatings, and their stress-strain curve, have been determined by depth sensing indentation tests with Berkovich and spherical tips, respectively. Erosion tests with normal incidence have been programmed to obtain the corresponding erosion rates. From the results of this work, the optimal projection conditions of stainless steel on carbon steel substrates for the repair of civil infrastructures subjected to erosion processes could be identified.