Synthesis and characterization of laser-based direct metal deposited nano-particles reinforced surface coatings for industrial slurry erosion applications

A nano-based material system resistant to the impingement of solid and liquid particles on the solid surfaces was developed by the laser-based direct metal deposition (LBDMD) process. The nano-based materials system contains 5% tungsten carbide (WC) nano-particles that are agglomerated with nickel–tungsten carbide 60 (Ni–Tung 60) by ball mill operation for slurry erosion resistance applications. Slurry erosion tests are performed on the LBDMD processed depositions using the ceramic proppant at different impingement angles using the abrasive water jet erosion testing machine. From these tests the amount of material removed, depth of penetration, and profile of the formed crater are computed as a function of the abrasive water jet impingement angles. The nano-based materials system exhibited better performance for slurry erosion resistance than the monolithic Ni–Tung 60 depositions and 4140 steels. In order to understand the role of the WC nano-particles influence on slurry erosion resistance and to understand the characteristic features of erosion surfaces, sub-surfaces, and the erosion mechanism, different advanced characterization tools are used.