Numerical Simulation and Experimental Validation of Surface Coatings Built by Laser Based Direct Metal Deposition (LBDMD) Process for Industrial Slurry Erosion Applications

摘要

A material failure model (MFM) called progressive damage initiation and propagation for the impingement of solid and liquid particles on the solid surfaces and pipe curvatures has been used to numerically simulate the slurry erosion process by using the commercially available 3D Finite Element Analysis (FEA) package ABAQUS/Explicit. Hence, the damage caused on the solid surfaces by the impingement of solid and liquid particles is called the 'slurry erosion'. The proposed model uses the FEA concepts adaptive meshing, strain-dependent damage initiation criteria, general contact algorithm, damage propagation, enhanced hourglass section control and multiple particle impingements.For the purpose of experimental validation and due to the availability of material properties, an All -LVC alloy steel surface coatings are deposited by Laser-Based Direct Metal Deposition (LBDMD) process. The slurry erosion tests are performed on these depositions using the ceramic proppant at different impingement angles using a centrifugal force driven erosion testing machine. From these tests the material removal rate (MRR) values, depth of penetrations, profiles of the craters are computed as a function of slurry jet impingement angles. The numerically computed results are compared with the experimental results and it is shown that they are in good agreement.