Numerical Simulation and Characterization of Slurry Erosion of Laser Cladded Surfaces by Using Failure Analysis Approach
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A material failure model (MFM) of progressive damage initiation and propagation for the impingement of solid and liquid particles on the solid surfaces was used to numerically simulate the slurry erosion process. The commercially available 3D Finite Element Analysis (FEA) package ABAQUS/Explicit was used to evaluate this problem. 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 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 an alloy of steel are deposited by the Laser-Based Direct Metal Deposition (LBDMD) process. The slurry erosion tests are performed on these depositions using the ceramic proppant at different impingement angles. The tests are made in a centrifugal force driven erosion testing machine. 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.
KeywordsLaser-based direct metal deposition Finite element analysis Adaptive meshing Material failure analysis Slurry erosion
The authors would like to acknowledge the financial support from Halliburton Energy Services through joining the NSF Industry University Co-operative Research Center for Laser Aided Manufacturing program. The authors would like to acknowledge Mr. Suresh Krishnan of ABAQUS South for his help with the numerical simulation; Mr. Michael Valant, Dr. Srdja Zekovic, and Dr. Vijay Soundararajan of SMU RCAM/CLAM for their help in performing the experiments and numerical simulation; Dr. Syed Hamid and Dr. Haoyue Zhang of Halliburton Energy Services for technical discussions; and Mr. Roy Beavers of SMU for SEM support. The A11-LVC steel alloy powders and Econoprop 20/40 are supplied by Carpenter Powder Products and Carbo Ceramics, respectively.
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