| Slurry erosion (the removal of material caused by the randomly moving high velocity liquid-solid particle mixture) is a serious issue in crude oil drilling, mining, turbines, rocket nozzles, pumps, and boiler tubes that causes excessive downtime and high operating costs as a result of premature part failure. The goal of this research is to enhance the service life of high-value components subjected to slurry erosion by utilizing the concept of functionally graded metal-ceramic composite material (FGMCCM) in which the favorable properties of metal (toughness, ductility, etc.) and ceramic (hardness) are tailored smoothly to improve erosion resistance. Among the potential manufacturing processes, such as the laser-based powder deposition (LBPD), the plasma transferred arc (PTA), and the thermal spray the LBPD process offers good composition and microstructure control with a high deposition rate in producing the FGMCCM. This research focuses on the development of nickel-tungsten carbide (Ni-WC) based FGMCCM using the LBPD process for applications the above mentioned.;The LBPD of Ni-WC involves the introduction of Ni and WC powder particle by an inert gas into the laser-formed molten pool at the substrate via nozzles. The LBPD of Ni-WC includes complex multi-physical interactions between the laser beam, Ni-WC powder, substrate, and carrier and shielding gases that are governed by a number of process variables such as laser power, scanning speed, and powder flow rate. In order to develop the best Ni-WC based slurry erosion resistant material using the LBPD process, the following challenges associated with the fabrication and the performance evaluation need to be addressed: 1) flow behavior of the Ni-WC powder and its interaction with the laser, 2) the effect of the process variables, the material compositions, and the thermo-physical properties on thermal cycles, temperature gradient, cooling rate, and residual stress formation within the material and the subsequent cracking issue, and 3) the effect of composition and composition gradient of Ni and WC on the slurry erosion resistance over a wide range of erosion conditions.;This thesis presents a set of numerical and experimental methods in order to address the challenges mentioned above. A three-dimensional (3-D) computational fluid dynamics (CFD) based powder flow model and three vision based techniques were developed in order to visualize the process of feeding the Ni-WC powder in the LBPD process. The results provide the guidelines for efficiently feeding the Ni-WC composite powder into the laser-formed molten pool.;The finite element (FE) based experimentally verified 3-D thermal and thermo-mechanical models are developed in order to understand the thermal and stress evolutions in Ni-WC composite material during the LBPD process. The models address the effect of the process variables, preheating temperature, and different mass fractions of WC in Ni on thermal cycles and stress distributions within the deposited material.;The slurry erosion behavior of the single and multilayered deposits of Ni-WC composite material produced by the LBPD process is investigated using an accelerated slurry erosion testing machine and a 3-D FE dynamic model. The verified model is used to identify the appropriate composition and composition gradient of Ni-WC composite material required to achieve erosion resistance over a wide range of erosion conditions. |
