Numerical Simulation and Characterization of Slurry Erosion of HVOF Coated Surfaces by Using Failure Analysis Approach

In present study an attempt was made to numerically simulate the slurry erosion process using material failure modelof progressive damage slurry erosion process was numerically simulated by using material failure model (MFM) of progressive damage instigation and promulgation for the impingement of solid and liquid particles on the solid surfaces. To simulate this problem Finite element analysis based three dimensional Abaqus Explicit software has been used. The mixture which comprises of solid and liquid particles known as slurry, when impinged upon the surface of the component surface leads to impingement of solid and liquid particles on the solid surface which leads to dreadful conditions on the surface known as slurry erosion. The proposed model uses the FEA concepts of adaptive meshing, strain-dependent damage initiation Criteria, a general contact algorithm, damage propagation, enhanced hourglass section control and multiple particle Impingements to study the slurry erosion process. For the purpose of experimental validation and due to the availability of material properties, surface coatings of a powder on steel are deposited by the HVOF Coating process. The slurry erosion tests are performed on these depositions using the abrasive slurry at different impingement angles. The tests are made in an Impact test erosion rig. From these tests, the material removal rate (MRR) values and depth of penetration including the profiles of the craters are computed as a function of the slurry jet impingement angles. The numerically computed results are compared with the experimental results and are shown to be in good agreement.