Optimization of solid particle erosion behavior of thermally sprayed nichrome on duplex stainless steel

Erosion stands as a formidable challenge within the industry, posing significant threats to pipeline integrity. This wear phenomenon occurs when minute solid particles collide with pipeline surfaces at specific angles and velocities. Given the pivotal role pipelines play in sectors like oil and industrial, their vulnerability to erosion wear presents a pressing concern. Solid particles inevitably accompany the fluids coursing through these conduits, subjecting them to erosion under harsh operational conditions. The repercussions extend beyond industrial realms, affecting both natural environments and societal well-being. Detecting and addressing erosion-induced damage promptly remains a daunting task, with potential leaks draining resources and disrupting operations. Unforeseen shutdowns further escalate operational costs and hinder productivity. Clearly, mitigating erosion wear is imperative for ensuring clean, safe, and efficient production processes. Consequently, industrial endeavors prioritize strategies to counteract erosion's deleterious effects. Technological advancements offer promising avenues for tackling this challenge. This investigation aims to devise effective solutions, focusing on the efficacy of a nickel–chromium erosion-resistant coating applied via atmospheric plasma spraying. A comprehensive analysis of erosion mechanisms and influencing parameters guides this endeavor. Through desirability analysis and Taguchi design of experiments, optimal parameters—flow velocity of 150 m/s, impact angle of 90°, discharge rate of 5 g/min, and 10 min duration—are identified. Notably, experimental results closely align with predictions, demonstrating a mere 3.03