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<p>This study evaluates the slurry erosion resistance of cold-sprayed WC-17Co ceramic coatings on CA6NM steel substrates used in hydro turbine blade applications. An artificial neural network (ANN) model was developed to analyze the effects of jet velocity (20–40&#xa0;m/s), impingement angle (30°, 60°, 90°), and slurry concentration (10,000–30,000&#xa0;ppm) on erosion behavior. A full factorial experimental setup comprising 27 runs was implemented. Results demonstrated that the WC-17Co coating reduced erosion-induced mass loss by 15–20% compared to uncoated steel. The ANN model showed high predictive accuracy, with <i>R</i><sup>2</sup> values exceeding 0.98 and mean prediction errors under 0.0025&#xa0;g. These findings highlight the combined effectiveness of cold spray coatings and ANN modeling in optimizing surface protection strategies for hydropower applications, thereby enhancing component longevity and reducing maintenance costs.</p>

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Artificial neural network modeling and experimental analysis of erosion resistance in tungsten carbide-coated CA6NM stainless steel

  • 期刊论文

  • 发表日期：

    2025年7月4日

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  • Harvinder Singh,
  • Binayak Sen,
  • Nitin Kumar,
  • Bharat Singh,
  • Abhijit Bhowmik,
  • Ankur Kumar,
  • Kaushal Kumar,
  • Vivek John

摘要

This study evaluates the slurry erosion resistance of cold-sprayed WC-17Co ceramic coatings on CA6NM steel substrates used in hydro turbine blade applications. An artificial neural network (ANN) model was developed to analyze the effects of jet velocity (20–40 m/s), impingement angle (30°, 60°, 90°), and slurry concentration (10,000–30,000 ppm) on erosion behavior. A full factorial experimental setup comprising 27 runs was implemented. Results demonstrated that the WC-17Co coating reduced erosion-induced mass loss by 15–20% compared to uncoated steel. The ANN model showed high predictive accuracy, with R2 values exceeding 0.98 and mean prediction errors under 0.0025 g. These findings highlight the combined effectiveness of cold spray coatings and ANN modeling in optimizing surface protection strategies for hydropower applications, thereby enhancing component longevity and reducing maintenance costs.