Research on the solid particle erosion wear of pipe steel for hydraulic fracturing based on experiments and numerical simulations

Erosion wear is a common failure mode in the oil and gas industry.In the hydraulic fracturing,the fracturing pipes are not only in high-pressure working environment,but also suffer from the impact of the high-speed solid particles in the fracturing fluid.Beneath such complex conditions,the vulnerable components of the pipe system are prone to perforation or even burst accidents,which has become one of the most serious risks at the fracturing site.Unfortunately,it is not yet fully understood the erosion mechanism of pipe steel for hydraulic fracturing.Therefore,this article provides a detailed analysis of the erosion behavior of fracturing pipes under complex working conditions based on experiments and numerical simulations.Firstly,we conducted erosion experiments on AISI 4135 steel for fracturing pipes to investigate the erosion characteristics of the material.The effects of impact angle,flow velocity and applied stress on erosion wear were comprehensively considered.Then a particle impact dynamic model of erosion wear was developed based on the experimental parameters,and the evolution process of particle erosion under different impact angles,impact velocities and applied stress was analyzed.By combining the erosion characteristics,the micro-structure of the eroded area,and the micro-mechanics of erosion damage,the erosion mechanism of pipe steel under fracturing conditions was studied in detail for the first time.Under high-pressure operating conditions,it was demonstrated through experiments and numerical simulations that the size of the micro-defects in the eroded area increased as the applied stress increased,resulting in more severe erosion wear of fracturing pipes.

Erosion Wear Behaviour of Kenaf/Glass Hybrid Polymer Composites

The awareness amongst the researchers to develop an environment friendly sustainable material leads to explore new class of plant-based fiber for making composites. Hybridization of such plant-based fiber with inclusion of engineered fiber is one of the promising methods to not only enhanced the mechanical performance but also suppressed the drawbacks that associate with such plant-based fiber to some extent. A usual hand lay-up method was taken-up in this work to fabricate four layered of hybrid kenaf(K)/glass(G)polyester laminates with different stacking order such as KKKK,KGKG,KGGK,GKKG and GGGG. The erosive character of the laminates was examined under three distinct particle velocities(48m/s, 70m/s,82m/s)and four different impact angles(30°, 45°, 60°, 90°). All fabricated laminates exhibited a semiductile character at lower velocities(48m/s and70m/s)as peak wear rate was observed at45° impact angle. However,they showed a semi-brittle character at high velocity(82m/s)as maximum rate of erosion was noticed at60° impact angle. Again,the influence of stacking order of piles on erosion wear was also clearly noticed. Moreover,the semi-brittle/semi-ductile characterization was also evidenced in accordance to the range of erosion efficiencies. The micro-structures of worn surfaces were inspected thoroughly from the images of scanning electron microscope(SEM)to evident the mechanism of erosion.

Effect of surface diffusion alloying on erosion wear property of ZM5 magnesium alloy

Specimens of ZM5 magnesium alloy were dipped into the mixed powder of Al and Zn at （390±5） ℃ for 8 h in argon gas protective environment and subjected to surface diffusion alloying processing （SDAP）. The erosion wear behaviors of ZM5 magnesium alloy before and after SDAP were investigated in two different erosion wear environments： oil and quartz environment; tap water and quartz environment. The surfaces of erosion wear specimens exhibited cutting scratch grooves in the oil and quartz environment. Corrosive attack was weak and cutting wear mechanism was responsible for the mass loss. When the erosion wear medium was changed to tap water and quartz environment, corrosion pits and cracks were obviously observed after erosion wear test. The corrosion from tap water and the scour from quartz intensified mass losses. Compared with the untreated specimens, the application of SDAP improved the erosion wear resistance in the same environment.

Erosion wear at the bend of pipe during tailings slurry transportation:Numerical study considering inlet velocity,particle size and bend angle

Pipeline hydraulic transport is a highly efficient and low energy-consumption method for transporting solids and is commonly used for tailing slurry transport in the mining industry.Erosion wear(EW)remains the main cause of failure in tailings slurry pipeline systems,particularly at bends.EW is a complex phenomenon influenced by numerous factors,but research in this area has been limited.This study performs numerical simulations of slurry transport at the bend by combining computational fluid dynamics and fluid particle tracking using a wear model.Based on the validation of the feasibility of the model,this work focuses on the effects of coupled inlet velocity(IV)ranging from 1.5 to 3.0 m·s^(-1),particle size(PS)ranging from 50 to 650μm,and bend angle(BA)ranging from 45°to 90°on EW at the bend in terms of particle kinetic energy and incidence angle.The results show that the maximum EW rate of the slurry at the bend increases exponentially with IV and PS and first increases and then decreases with the increase in BA with the inflection point at 60°within these parameter ranges.Further comprehensive analysis reveals that the sensitivity level of the three factors to the maximum EW rate is PS>IV>BA,and when IV is 3.0 m/s,PS is 650μm,and BA is 60°,the bend EW is the most severe,and the maximum EW rate is 5.68×10^(-6)kg·m^(-2)·s^(-1).In addition,When PS is below or equal to 450μm,the maximum EW position is mainly at the outlet of the bend.When PS is greater than 450μm,the maximum EW position shifts toward the center of the bend with the increase in BA.Therefore,EW at the bend can be reduced in practice by reducing IV as much as possible and using small particles.

A review of biomimetic research for erosion wear resistance

One of the reasons behind failed engineering surfaces and mechanical components is particle erosion wear;thus,to mitigate its happening,biomimetic engineering is the current state-of-the-art being applied.Hence,this paper reviews the literature and the development trends on erosive wear resistance that employ biomimetic methods as well as analyze the bio-inspired surface,the bio-inspired structure,the bio-based materials,the associated challenges,and the future trends.Furthermore,the feasibility of the multi-biological and perspective on the coupling biomimetic method for anti-erosion wear are studied.It is concluded that the design of anti-erosion materials or structures by the bio-inspired methods is of great significance in the development of engineering applications.

EROSION WEAR OF AlSi-GRAPHITE AND Ni/GRAPHITE ABRADABLE SEAL COATINGS

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Erosive Wear Study of PPLSF/Glass Fiber Reinforced Hybrid Laminates

This work is focused to examine the erosive performance of hybrid Palmyra palm leaf stalk fiber(PPLSF)/glass polyester laminate against solid particle bombardment.A hand lay-up method was adopted for the fabricating four piles of five distinct laminates with different stacking order glass and PPLSF layers.Amongst them,one group of pure PPLSF and pure E-glass laminates were fabricated.The hybrid laminates were exposed to high speed stream of solid sand particle at three distinct impact velocities(48,70 and 82 m/s)and four different angles of impingement(30°,45°,60°and 90°).The effect of particle velocity,angle of impingement and stacking order on both wear rate and efficiency were highlighted.The experimental assessment reveals a significant improvement in erosive wear resistance properties due to hybridization of PPLSF with E-glass.Again,the laminates with PPLSF layer as skin and glass as core layer exhibited better erosive wear resistance properties than other types of laminates.Further,a maximum value of erosion at lower velocity(48 m/s)is also noticed at 45°impingement angle.However,at high velocity of impact 70 m/s and 82 m/s,the maximum rate of erosion has been shifted from 45°impact angle to 60°impact angle.The alternation of this semi-ductile character to semi-brittle character is evidenced by analyzing the experimental data.Further to justify the mode of erosion,the eroded surface samples were inspected by scanning electron microscope(SEM).

Effect of Filler Content and Alkalization on Mechanical and Erosion Wear Behavior of CBPD Filled Bamboo Fiber Composites

In this study the mechanical and erosion wear behavior of bamboo fiber reinforce epoxy composites filled with Cement By-Pass Dust (CBPD) were studied. The effect of CBPD content and alkalization on the various properties of these composites was also investigated. Taguchi’s orthogonal arrays are used for analysis of experiential results. It identifies significant control factors influencing the erosion wear and also outlines significant interaction effects. Analysis of variance (ANOVA) test has also been performed on the measured data to find the most significant factors affecting erosion rate. Finally, eroded surfaces of both untreated and alkali treated bamboo fiber reinforced composites were characterized using SEM.

Morphology and solid particle erosion wear behavior of red mud composite coatings

In order to understand the tribological behavior of red mud composite coatings, the red mud and composite materials like fly ash, carbon and aluminum are being plasma sprayed. The coatings are investigated to know their morphological behavior and erosion wear characteristics. Plasma spraying is done at different plasma arc current like 200, 250, 300 and 400 amperes. Torch input powers maintained as 6, 9, 12 and 16 KW. The substrates chose are rectangular in shape having a dimension of 50 mm × 25 mm × 2 mm. commercially available aluminum, copper, mild steel and stainless steel being used as substrate. Room temperature solid particle erosion trials are carried out using a compressed air blasting type rig under impact angles of 30o, 60o and 90o. The present investigation uses an erosion apparatus of Sand Blast type. The test is conducted as per ASTMG-76 standards. It is analyzed that initially the cumulative coating mass loss increases rapidly and later on becomes almost stagnant. A transient regime in the erosion process exists, during which the incremental erosion rate decreases monotonically down to a steady state erosion rate.

Erosion wear behaviour and mechanism of abradable seal coating

The erosion wear behaviour and mechanism of several middle temperature seal coatings were investigated by a CMS 100 self made vacuum sand erosion machine. The results show that the relationship between the erosion mass loss and the erosion time is linear, the coatings hold a maximum erosion rate at 60° impact angle, and the relationship between the erosion rate and the impact speed is an exponential function. The speed exponent increases with the increase of the impact angle. At 90° impact, indentations and extruded lips were generated on the coating surface subjected to impact. With repetitive impact by the abrasive particles, the extruded lips were work hardened and peeled off, while flattened metal phase grains were impacted repeatedly, loosed and debonded. At 30° impact, the erosion wear of the coating is characterized by micro cutting, plowing and tunneling via pores and non metal phase. The model of the erosion mechanism is advanced on the basis of the above mentioned erosion wear behaviour.

Erosive Wear and Wear Mechanism of in situ TiC_P/Fe Composites

The base structure of in situ TiCp/Fe composites fabricated under industrial condition was changed by different heat treatments. Erosive wear tests were carried out and the results were compared with that of wear-resistant white cast iron. The results suggest that the wear resistance of the in situ TiCp/Fe composite is higher than that of wear-resistant white cast iron under the sand erosive wear condition. The wear mechanism of the wear-resistant white cast iron was a cycle process that base surface was worn and carbides were exposed, then carbides was broken and wear pits appeared. While the wear mechanism of in situ TiCp/Fe composite was a cycle process that base surface was worn and TiC grains were exposed and dropped. The wear resistance of in situ TiCp/Fe composite was lower than that of wear-resistant white cast iron under the slurry erosive wear condition. Under such circumstance, the material was not only undergone erosive wear but also electrochemistry erosion due to the contact with water in the medium. The wear behaviours can be a combination of two kinds of wear and the sand erosive wear is worse than slurry erosive wear.

Effect of Liquid and Gas Velocities on Magnitude and Location of Maximum Erosion in U-Bend

Solid particle erosion is a micromechanical process that is influenced by flow geometry, material of the impacting surface, impact angle, particle size and shape, particle velocity, flow condition and fluid properties. Among the various factors, particle size and velocity have been considered to be the most important parameters that cause erosion. Particle size and velocity are influenced by surrounding flow velocities and carrying fluid properties. Higher erosion rates have been observed in gas-solid flow in geometries where the flow direction changes rapidly, such as elbows, tees, valves, etc, due to local turbulence and unsteady flow behaviors. This paper presents the results of a Computational fluid dynamic (CFD) simulation of dilute gas-solid flow through a U-Bend and the dynamics behavior of entrained solid particles in the flow. The effect of liquid and gas velocities on location of erosion were investigated for 50, 100, 150, 200, 250 and 300 microns sand particles. Three different fluid velocities of 15, 30.48 and 45 m/s were used in the CFD analysis. The magnitude and location of erosion presented in the paper can be used to determine the areas susceptible to maximum erosive wear in elbows and U-bends, along with corresponding rate of metal loss in these areas.

Solid particle erosion studies of thermally deposited alumina-titania coatings on an aluminum alloy

Thermal barrier coatings are widely used as surface modifications to enhance the surface properties of the material and protect from surface degradations such as erosion and corrosion.Ceramic-based coatings are highly recommended to increase wear resistance in the indus-trial sector.In this paper,an alumina-titania ceramic powder was deposited on an aluminum alloy using an atmospheric plasma spray tech-nique.Experimental investigations were performed to study the behavior and erosion rate of the material.Solid particle erosion studies were performed by varying the particle velocity and particle flow rate.The angle impingement and stand-off distance were constant for comparison.The base metal has a clinging effect and the mass change was negative at a maximum particle flow rate of 4 g·min^(−1).Under the same process conditions,the coated sample had a reduced lifetime and reached a maximum erosion rate of 0.052(Δg/g).The solid particle erosion studies confirmed that the base metal aluminum alloy had severe surface damage with erodent reinforcement when compared to the coated samples.The influence of the particle velocity,particle flow rate,and input process parameters were also identified.

Taguchi approach to influence of processing parameters on erosive wear behaviour of Al7034-T6 composites

Taguchi technique was used to predict the influence of processing parameters on the erosive wear behavior Al7034-T6composite reinforced with SiC and Al2O3particles in different mass fractions.These hybrid metal matrix composites(HMMCs)werefabricated by using a simple technique called stir casting technique.Scanning electron microscope(SEM)was used to study thesurface morphology of the composite and its evolution according to processing time.The design of experiment(DOE)based onTaguchi’s L16orthogonal array was used to identify various erosion trials.The most influencing parameter affecting the wear rate wasidentified.The results indicate that erosion wear rate of this hybrid composite is greatly influenced more by filler content and impactvelocity respectively compared to other factors.This also shows the significant wear resistance with the increase in the filler contentsof SiC and Al2O3particles,respectively.

RESEARCH ON EROSION OF SILICON CARBIDE CERAMIC BLADE

In this paper, three linds of silicon carbide ceramic materials are chosen to perform the tests of material erosive wear. The relationship of ambient parameters, abrasive property and target property is studied in these experiments. Some main factors affecting erosive wear rate are determined by analysis of testing results, step wise regression analysis is completed according to the nondimensional quantities obtained by dimensional analysis. Relative hardness (partide to target Hp/Ht and erosion factor (Hpd1/2/Kic) are put for-ward to evaluate erosion property.

DEVELOPMENT OF NEW EROSION-CORROSION RESISTANT CUPRONICKEL ALLOYS

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Effect of impinging angle and rotating speed on erosion behavior of aluminum

Commercial aluminum（grade 1900） in rotary motion was exposed to slurry of sand in water.Samples were mounted at various angles and rotated at different speeds.Wear rate was calculated using mass loss measurement.The results show that wear rates increase with increasing impingement angle up to 90°.Contrary to the conventional understanding of maximum loss of ductile material at about 45° impingement angle,maximum wear rate was observed in case of the aluminum sample fixed at 90°.However,increasing rotation speed of the samples results in exponential increase in wear rate.The findings are substantiated with the metallographic study of worn surface.

Numerical study on erosion behavior of sliding sleeve ball seat for hydraulic fracturing based on experimental data

The sleeve sealing ball seat is one of the important components in the multistage fracturing process of horizontal wells.The erosion and wear of the surface will decrease the sealing performance of the fracturing ball and the ball seat.This leads to pressure leakage during the fracturing process and fracturing failure.In this paper,combined with the actual ball seat materials and working conditions during the fracturing process,the erosion tests of ductile iron and tungsten carbide materials under different erosion speeds,angles,and mortar concentrations are carried out.Then the erosion test results were analyzed by mathematical fitting,and a set of erosion models suitable for sliding sleeve setting ball seat materials were innovatively established.For the first time,this paper combines the erosion model obtained from the experiment and the computational fluid dynamics(CFD)with Fluent software to simulate the erosion of the ball seat.Based on the simulation results,the morphology of the sliding sleeve seat ball after erosion is predicted.Through analysis of the test and simulation results,it is showed that the erosion rate of tungsten carbide material is lower and the wear resistance is better under the condition of small angle erosion.This research can offer a strong basis for fracturing site selection,surface treatment methods,and prediction of failure time of ball seats.

Analysis on cavitation erosion resistance of isostatic graphite

Isostatic graphite materials with 8%porosity and 14%porosity were prepared by the cold isostatic pressing process.Cavitation erosion resistance of the isostatic graphite was evaluated through cavitation tests in an ultrasonic vibration system.The volume loss and erosion morphology of the isostatic graphite were adopted to investigate the cavitation erosion resistance of the isostatic graphite.The cavitation test results show that after ultrasonic vibration of 14 h,the volume loss of the isostatic graphite materials with 8%porosity and 14%porosity are 35%and 46%of the carbon graphite material,respectively.The isostatic graphite material with 8%porosity exhibits an outstanding capability to resist cavitation erosion damage,and the cavitation erosion resistance of the isostatic graphite enhances with the decrease in porosity.The damage mechanism of isostatic graphite is brittle fracture attributed to the shock wave and micro jet.The isostatic graphite with low porosity exhibits excellent cavitation erosion resistance due to its fine graphite particles,homogeneous structure and high degree of hardness.

Solid Particle Erosion Behaviour of TiN Coating on AISI 4140 Steel

In this study, the performance against erosive wear of PVD TiN (titanium nitride) coating was evaluated using an erosion test rig similar to that described in the standard ASTM G76-95. This coating normally has various industrial applications such as tapping, drilling, dry machining and punching. Angular silicon carbide (SiC) was used as an abrasive particle with a grain size of 350-450 μm. Erosion tests were carried out using different incident angles, 30°, 45°, 60° and 90° with a particle velocity of 24 ± 2 m/s, an abrasive flow rate of 0.7 ± 0.5 g/min, and the test temperature was between 35°C and 40°C. The particle velocity and the abrasive flow rate were low in all of the tests to reduce the interaction between the incident and the rebounding particles in the system. The surfaces were examined with a scanning electron microscope (SEM) to characterize the erosive damage. The wear mechanisms identified were brittle fracture characterized by radial cracks on the surface by multiple impact and a few pits at 30°, while a few cracks and the formation of craters in random positions were observed at angles near or at 90°. Elliptical scars were observed at 30° and 45°, which are a characteristic feature when the specimens are impacted at low-incident angles (α ≤ 45°) whereas a roughly circular scar was seen at 60° and 90°. In addition, roughness variations were analyzed using atomic force microscopy (AFM), before and after the erosion tests, and the results exhibited an increase in the roughness as the TiN samples were impacted at angles near or at 90°.