28/07/25
An Australian specialist in cold spray additive manufacturing, Titomic offers advanced solutions for the repair and protection of critical metal components. Their unique technology enables material deposition without fusion, avoiding thermal stress and preserving the structural integrity of parts.
In this case study, discover how Titomic tackled a major challenge in the Australian rail industry: the fast, non-intrusive restoration of a traction motor shaft damaged by wear and corrosion. Using its TKF9000 system, Titomic applied a high-performance nickel coating, significantly reducing repair lead times while ensuring durability and precision.
A concrete demonstration of the potential of cold spray technology in the maintenance of critical assets.
A problem beyond the rails – wear and corrosion cost over 60 billion dollars annually.
A major Australian railway company faced significant wear and corrosion issues on a traction motor shaft, particularly around the bearing contact zone. Over time, the bearings caused wear to the shaft surface, leading to undersized and degraded areas.
This wear and degradation resulted from high dynamic loads and various harsh environmental conditions. Traditional repair methods required full disassembly of the shaft assembly, greatly increasing repair time.
To restore the part to specification, the TKF9000 was used to deposit an exclusive nickel powder blend onto the shaft. This nickel coating reestablished the required tolerances and provided a new surface resistant to both wear and corrosion.
Titomic’s engineers developed a unique solution to address this challenge. A specially formulated nickel powder was selected to coat the worn shaft area, forming a robust surface layer. This coating was then machined to the final required dimension, restoring the original design tolerance between the bearing and shaft.
Worn part.
Part installed on the TKF9000.
Part coated with nickel.
Finished part after machining.
The test phase consisted of a series of rigorous evaluations, including shear tests, thermal cycling tests, and microstructural analysis. These confirmed the strength and effectiveness of the cold spray deposit.
The cold spray repair process proved to be highly effective and cost-efficient. Titomic was able to machine and spray the shaft coating in just a few hours. Since cold spray generates no heat-affected zone, the shaft’s integrity remained fully intact. Additionally, the repair could be performed without disassembling the upper assembly, drastically reducing intervention time and keeping the train in service.
This solution marked a breakthrough, offering a faster and more practical alternative to conventional repair or replacement methods.
Source: Critical Asset Maintenance For Australian Trains, Titomic, 10/12/2023.
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