COMPREHENSIVE MODELING OF THE EFFECT OF MULTIPHASE HARDENING ON THE WEAR AND CORROSION RESISTANCE OF STRUCTURAL STEELS IN MARINE ENVIRONMENTS

Abstract

The paper presents the results of a comprehensive numerical modeling of the effect of multiphase hardening on the behavior of surface layers of structural steels in marine operation. The model combines three stages of surface treatment: laser hardening, electric spark alloying, and cold spray spraying. An approach to analyzing the thermomechanical interaction between the hardened layers was implemented, and the electrochemical activity of materials in salt water was taken into account. The simulation results showed that the thickness of the cold spray coating significantly affects the distribution of residual stresses, and the interfacial electrode potential difference can lead to galvanic corrosion when the critical threshold of 0.35 V is exceeded. The constructed graphs and 3D profiles allow us to accurately identify the risk areas of localized failure due to overload or corrosion. The proposed approach allows not only to predict the mechanical behavior of a multiphase coating under load, but also to take into account corrosion risks arising from potential incompatibility of layer materials. The modeling was performed in COMSOL Multiphysics using multiphysics modules covering thermal conductivity, stress-strain state, and electrochemical processes. This integrated approach makes it possible to optimize the design of the coating and technological parameters of hardening taking into account real operating conditions, which is especially important for dual-purpose equipment for marine, defense, and energy.The results obtained are of practical importance for the design of hardened structures of technical systems and equipment, including hull elements, submersible units, turbines, screw gears, and other parts operating in aggressive environments.