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Coating solutions to fight cavitation
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Cavitation protection
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  2. Solutions
  3. Cavitation Protection Coatings

Coatings for cavitation protection

Cavitation – an almost unknown force. For many the unthinkable: Small water bubbles dissolve the most massive metal structures within a short time. Localized damages, virtually as sharp-edged as a laser beam. Indeed, the enormous bundling of energy is physically based on a little explosion followed by an implosion of the air bubble. And cavitation is just as loud – unmistakably similar to rockfall.

Metallic microstructures are susceptible to the permanent, shock-like alternating loads of compression and tension. Embrittlement is a fact of life. Thermal repair processes turn out to be additionally problematic here - the undesirable change in microstructure (hardening) can even aggravate the problem and additionally cause cracking!

Cavitation protection - we would like to take care of your problems Objectives Resilient, elastic materials are best suited to tolerate alternating push and pull forces. Solid surfaces tend to become brittle or develop partial pitting corrosion. This sooner or later causes dramatic weakening of the component statics and ultimately leads to technical and economic complete failure. Protective coatings from MetaLine make sure that the original component geometry, its basic substances and the required mechanical strength is kept. The coating itself does not have an unlimited lifetime due to these destructive effects. But it may be replaced by far easier and also more cost-effective than the component. Or put in other words, the coating serves as a predetermined wear protection layer recyclable as required. Also, the low area weight amounting to only 1.05 kg/m²/mm and the smooth surface geometry improve the energy efficiency (effectiveness) far better than thermo-metal or ceramic protective systems. Technical solutions in detail MetaLine Series 700 - plane, even and flow-harmonic surfaces to reduce turbulences. Elastic cavitation protection preventing substance degradation – a different way of surface protection.
The permanent change of pressure and tension can best be counteracted by a resilient, elastic material. Otherwise sooner or later a weakening of the static stability can ultimately lead to technical and financial losses. Protective coatings from MetaLine ensure the original component geometry. The mechanical surface strength is kept intact. However, even these specialized coatings have not an unlimited lifetime, given these destructive effects. But it is simpler and less risky – compared to thermal treatments – plus significantly less expensive to replace. Better said, the coating serves as a regenerable wear protection layer that can be renewed at any time. Also, the low area weight amounting to only 1.05 kg/m²/mm (0.22 lbs/ft2/40 mils) and the smooth surface geometry improve the fluid-flow efficiency far better than thermo-metal or ceramic protective systems. MetaLine Series 700 – plane, even and flow-harmonic surfaces to reduce turbulences. Elastic cavitation protection preventing substance degradation – a different surface protection method.

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Series 700 Presentation: All Industries
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Objectives

The permanent change of pressure and tension can best be counteracted by a resilient, elastic material. Otherwise sooner or later a weakening of the static stability can ultimately lead to technical and financial losses.

A MetaLine protective coating preserves the component geometry, prevents substance degradation and ensures full static stability. However, the coating does not have an infinite lifetime under such destructive effects! It considerably delays cavitative attack and is easier and cheaper to repair than a worn metallic structure. In other words, the coating serves as a target wear protection layer that can be regenerated at any time and ensures the original static strength.

Also, the low area weight amounting to only 1.05 kg/m²/mm (0.22 lbs/ft2/40 mils) and the smooth surface geometry improve the fluid-flow efficiency far better than thermo-metal or brushed on epoxy-ceramic systems.

Technical solutions in detail

MetaLine Series 700 –

smooth, even and flow-harmonious surfaces to reduce turbulence. Elastic cavitation protection that minimizes substance degradation - a somewhat different approach that also combats the cause of damage and not just its consequences!

More information

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Explained in simple terms...

Rudder coating – MetaLine 785 being used as high-end cavitation resistant coating for the most troublesome rudder belonging to a big container ship (10,500 TEU)
Francisturbinecoating – 2 mm MetaLine 785 protects this runner at the most impacted areas as a so-called softcoating system
Cavitation protection – MetaLine 785 is used as OEM-serial coating on BWT-reactors for the treatment of ballast water by use of cavitation forces
Tunnel thruster coating - electrochemical corrosion, cavitation, erosion. A dangerous mixture based on an energetic overload of the steel structure. The energy absorbing MetaLine 785 is the physically correct solution to cope with the situation.
MetaLine 785 being used on alumina ship propellers for long-term protection against salt-water oxydation and cavitation
Stevencoating – a sprayable heavy duty cavitation protection for the durable treatment of this steven
Cooling water systems, mainly at coastal sites, require special protective systems – MetaLine Series 700 provide detailed solutions for many applications
Shut-off valve coated with MetaLine 785 – permanent protection against solid impact and corrosion
Francis impeller of a small hydroelectric power plant near the German river Inn coated with MetaLine – especially difficult to carry out due to the small blade distance
Quite unusual and not due to the book – a Francis impeller coated partially with MetaLine 785 in place without removing it
Francis impeller coating - what matters? A smooth and uniform surface, vibration resistance, impact-resistant rubber-like properties, tremendous adhesion, expertise - ask for MetaLine 785, because your impeller deserves no less!
Francis turbine coating – MetaLine 785 protects this big turbine impeller. The coating was applied directly for the turbine manufacturer as OEM supplier. Smoothness and fluid flow characteristics are impressive
Kaplan coating - Kaplan turbine runner coated with MetaLine 590 from a French power plant on the Lower Rhine. The MetaLine coatings are always also repairable just in case
Designed for special applications – 2,5 mm MetaLine 785 as professional – lightweight – cavitation protection
Pump component of a drinking water supply in Lisbon – coated with 2 mm MetaLine Series 700
Turbine apparatus in a pump storage power station in Luxembourg coated with MetaLine Series 700
Hydroturbine coating - water inlet spiral of a Francis turbine in the area of the Swiss Gotthard massif coated with 2.5 mm MetaLine 785. Annual inspection reports since 2006 are available
Pump casing protection – one of the biggest pump casings every coated with MetaLine Series 700. It is an unusual welding construction designed for a chinese hydro pumping station
Blade coating – MetaLine 785 had been applied completely smooth in a thickness of about 1,5 mm to these ventilator blades. Means the alumina-construction is perfectly protected against wear & tear
A coating with 4 mm MetaLine 785 helps the operator of this Portuguese Power Plant sleep better at night
Axially split pump housing coated with 2.5 mm MetaLine 785. Application site "yellow river in China". Under "Service/Company/References" you will find pictures of the casing after 4 years in operation - you will be surprised!
Vertical Kaplan turbine coating - an unusual case because the customer had coated the runner and the casing elastomerically. In total, 3 identical turbines were treated very successfully at a dam stage in France.
Blade support of a vertical Kaplan turbine - massive wear of up to 5 mm was recontoured with MetaLine 785 and the entire hood was given a protective coating. The cavitative attack at this plant in northern Spain is simply too high for unprotected operation.
Horizontal Kaplan turbine pipe coating - You would like to have more information about this application and the customer experience? Please contact us by phone and we will discuss. But please understand that we do not put customer data freely available on the Internet. Thank you!