Enhancement of Corrosion and Wear Resistance in Maritime Propeller Systems through Copper Electroplating on Nickel based Superalloys

Abstract

Thin coatings applied to surfaces are extremely important in industrial applications because they protect base materials against wear, corrosion and other surface-related hazards. Extensive study has been performed in the field of maritime engineering, where standard steel propellers are highly prone to corrosion, to investigate improved alternatives such as nickel-based superalloys. These superalloys are notable for their lightweight qualities and outstanding corrosion resistance, making them a possible replacement for ordinary steel propellers. Electroplating, specifically the deposition of a copper coating onto nickel-based superalloy substrates, is the primary focus of this research effort. The goal is to build a protective copper covering that is up to 10 microns thick. The primary purpose of this research is to improve the ability of the nickel-based superalloy to endure wear, corrosion and general surface deterioration by methodically altering process parameters during electroplating. The key objective is to improve the copper coating process in order to achieve maximum efficiency. A complete set of experiments was performed to evaluate the performance of the coated surfaces. The resistance to wear was examined using the pin-on- disc method, while the resistance to corrosion was investigated using salt spray testing in a controlled environment with an ASTM B-117-compliant NaCl solution. Brinell hardness testing was also used to determine the hardness of the coated samples. Furthermore, the microstructure of the coated surfaces was painstakingly studied using Scanning Electron Microscopy (SEM) to gain vital insights into the structural properties and integrity of the copper-coated nickel-based super alloy.