Numerical Simulation Of Erosive Wear Properties Of Plasma Sprayed Coatings

Due to the special natural environment in Xinjiang,the surface coating of metal materials has been in the environment of erosive and corrosive media such as strong wind,sand,high mineralization,etc.The coupling between them will further deteriorate the fatigue resistance of the material and cause equipment failure.Therefore,the research on the erosion and corrosion wear of materials has become a key problem that scholars need to solve urgently.In this paper,according to the wear condition of the coating,the erosion wear rate of the coating under different medium conditions is studied,and the erosion damage state of the coating is predicted.The research results are of great help to formulate corresponding measures to alleviate the erosion behavior,and to prolong the service life of the equipment or parts,and to improve the economic benefits.Based on WC-12 Co coating by plasma spraying in this paper,the erosion and wear test of plasma sprayed composite coating under the two-phase flow of wind and sand was carried out by a self-made dry sand mold erosion and wear machine at room temperature.Through the erosion test of plasma sprayed composite coating under the two-phase flow of sand and wind,the failure law of coating erosion and wear under the action of wind-sand erosion is obtained,and the wear mechanism and damage law of sand and wind erosion are revealed.Combined with the fluid dynamics software FLUENT,the influence of different factors on the erosion wear performance and the erosion wear mechanism are studied by the method of experiment and simulation.The results show that under different wind speed,particle diameter,erosion angle and particle mass flow rate,the erosion wear rate of the coating changes to some extent.By observing the microstructure,it can be concluded that the failure form of the coating is micro cutting erosion at 30 °and fatigue peeling at 90 °.Using the finite element simulation software ANASYS-FLUENT,the wear behavior and the wear process of the coating was simulated under changing the wind speed,particle diameter,erosion Angle and particle mass flow rate by using the standard k-?model,DPM model and Euler multiphase flow model.The wear condition of the coating was simulated in the environment of gas-sand,gas-sand-liquid,and gas-sand-liquid-salt media respectively.The results show that: 1)With the increase of wind speed,the wear rate of the coating increases;2)When the particle diameter continuously increases,the wear rate of the coating gradually increases;3)When the angle increases,the wear rate of the coating increases first and then decrease,when the erosion angle is 60 °,the erosion wear of the coating is the most serious,followed by 90 °,and the smallest at 30 °;4)When the particle mass flow rate increases,the wear rate of the coating gradually increases.The failure behavior of the coating under the coupling effect of gas-sand-liquid-salt erosion and corrosion environment is studied,and then the factors influencing the wear behavior and the mechanism of the coating erosion corrosion wear were explored.By comparing the simulation results of multiphase flow erosion corrosion with the simulation results and experimental results of the two-phase flow of wind and sand,it is found that the change trend is consistent with that of the two-phase flow of wind and sand,and the feasibility of the numerical simulation method of multiphase flow erosion and corrosion is verified.The wear rate of coating increases with the increase of medium.The cloud diagram of the equivalent stress on the coating surface was obtained by fluid-solid coupling,the changes of wind speed and diameter increase the stress and wear rate of the coating,When the angle changes,the force on the coating changes.