Study On The Simulation And Experiment Of Wear Resistance Of The Arc Spraying Coating

Serious high temperature erosion wear on the boiler tubes of coal-fired power plants hascaused enormous economical losses and the reduction of equipment's lifespan at home andabroad. Resistance to high temperature erosion of metallic materials has become the keyfactor of the equipment design. The supersonic arc spray technology is a new surfacestrengthening technology with low cost, high efficiency and good surface quality. Producingthe wear resistance coating on T91-steel, which is the common material used in boiler tubes,by supersonic arc spraying has quite good applied effect and economic benefit.The paper could be divided into two sections. The first section is mainly about thenumerical simulation analysis techniques for erosive wear and abrasive scratching. Firstly, themodels of erosive wear were established by meshfree simulation technique and FE (finiteelement) method. The influence of the impact angle and impact velocity on the weight loss oftarget material was investigated. The erosion failure mechanism of ductile material wasexplained. Secondly, a FE model of erosive wear on ductile with cohesive element wasestablished. Simulation results show the shear stress at the interface between the coating andthe substrate causes the beginning of the cracking of the coating. The physical mechanism ofcircumferential crack was analysed. Lastly, a model with the coupling algorithm of smoothedparticle hydrodynamics (SPH) scheme and FE mesh was used to simulate single diamondscratching of Ti6Al4V target material. The change rule of the cutting force and the normalforce with cutting depth and speed varies were investigated. Simulation analysis hasimportant guiding significance to the single diamond scratch test and the errosion test.The second section of this paper is mainly about tests. Micro-hardness, adhesion strengthand phase compositions of the coatings were tested and observed. According to the formerresults, wear resistance tests were carried. For the scratch test, the influence of scratchingvelocity and load on the cutting force and normal force were investigated. For the hightemperature erosion test, the temperature was set at25?and650?, the influence of impactangel and temperature on the weight loss of target material were investigated. Experimentalstudy on scratching wear and erosive wear at highte mperature provides an effectivemethodology to predict the wear-resistance of electric arc spraying coats.