WCB阀门材料气固冲蚀实验与模拟研究

石维渺; 程金亮; 肖杰; 周念涛; 卢俊安; 黄玖辉; 何龙; 林元华

doi:10.16490/j.cnki.issn.1001-3660.2026.11.016

PDF(4999 KB)

表面技术 ›› 2026, Vol. 55 ›› Issue (11) : 183-195. DOI: 10.16490/j.cnki.issn.1001-3660.2026.11.016

摩擦磨损与润滑

WCB阀门材料气固冲蚀实验与模拟研究

石维渺¹, 程金亮¹, 肖杰¹, 周念涛¹, 卢俊安², 黄玖辉³, 何龙⁴, 林元华^1,*

作者信息 +

Experimental and Simulation Study on Gas-Solid Erosion of WCB Valve Materials

SHI Weimiao¹, CHENG Jinliang¹, XIAO Jie¹, ZHOU Niantao¹, LU Jun'an², HUANG Jiuhui³, HE Long⁴, LIN Yuanhua^1,*

Author information +

文章历史 +

摘要

目的通过气-固实验和冲蚀模拟来探究排污阀现场材料WCB的气固冲蚀特性。方法以现场的阀门-WCB材料作为研究对象,采用符合ASTM G76标准的高速气体射流冲蚀实验装置,系统考察冲击角度（45°~90°）、气流速度（36~72 m/s）和颗粒质量流量（2~4 g/min）对材料冲蚀行为的影响;结合扫描电子显微镜、白光干涉仪、激光粒度分析仪和硬度计等表征手段,分析损伤形貌与材料性能响应机制;基于实验数据对Ahlert冲蚀模型进行重新标定,构建了WCB材料的冲蚀速率方程,将其嵌入CFD数值模拟的壁面回弹条件,建立能够准确反映实际冲蚀规律的预测模型。结果材料冲蚀速率随冲击速度和颗粒质量流量的增大而单调递增,而与冲击角度呈负相关,在45°时材料损失最为严重。微观分析表明,冲蚀机制随角度增加发生明显转变：中低角度（45°~60°）下表现为以塑性犁削为主、脆性微裂纹为辅的混合模式;高角度（75°~90°）下则转为颗粒嵌入引起的表面压实与层状剥落为主导。数值模拟验证了入口压力与冲蚀速率呈正相关,同时表明颗粒粒径和形状系数（球形度）均与冲蚀速率呈负相关。结论 WCB阀门材料的冲蚀机制随冲击角增大呈现典型的“韧-脆”转变特征,90°垂直冲击时脆性剥落成为主导失效模式。所建立的冲蚀速率方程预测精度高,模拟与实验趋势一致,研究结果可为页岩气开采过程中阀门的抗冲蚀设计提供依据。

Abstract

In the challenging domain of unconventional natural gas exploitation, specifically during the critical subsequent flowback and production phases, the reliable operation of blowdown valves is frequently compromised. These valves are subject to an extremely aggressive working environment characterized by high-velocity gas-solid two-phase flow, which inevitably contains hard solid particles such as aluminum oxide (Al₂O₃) proppants. This phenomenon induces severe erosion wear on the internal components of the valves, leading to a progressive deterioration of their structural integrity. Consequently, this often results in premature valve failure, dangerous fluid leakage, and significant unplanned downtime, thereby posing substantial safety risks and economic losses to the entire extraction process. Therefore, the work aims to conduct an in-depth investigation into the erosion characteristics and failure mechanisms of the WCB material, which is a common construction material for field valves. By utilizing a state-of-the-art high-speed gas jet erosion testing apparatus that complies with the ASTM G76 standard, the effect of key operational parameters is systematically evaluated. Furthermore, a robust and accurate predictive model is established through the integration of experimental data and computational fluid dynamics (CFD), which can ultimately serve as a scientific guideline for the anti-erosion design and lifespan assessment of valves in the demanding context of shale gas recovery. The research methodology commenced with erosion experiments conducted on a high-velocity gas jet rig complies with the ASTM G76 standard. The effect of three critical variables-impact angle (45°-90°), gas velocity (36-72 m/s), and particle mass flow rate (2-4 g/min)-on the erosion behavior of WCB was systematically evaluated. Upon exposure, the eroded samples underwent comprehensive characterization to decipher the underlying damage mechanisms. This involved the use of scanning electron microscopy (SEM) for micro-morphology analysis, white light interferometry for 3D surface topography, laser particle size analysis, and Vickers microhardness testing. Based on the acquired experimental dataset, the empirical constants within the Ahlert erosion model were recalibrated to derive a material-specific erosion rate equation for WCB. This customized equation was subsequently integrated into the boundary conditions of a CFD simulation framework, specifically governing particle-wall interactions, to establish a high-fidelity predictive model. The experimental findings revealed that the erosion rate of WCB increased monotonically with the rising impact velocity and particle mass flow rate. Conversely, a negative correlation was observed with respect to the impact angle, with the maximum erosion severity recorded at a glancing angle of 45°. Microstructural analysis indicated a distinct transition in the dominant erosion mechanism as the impact angle increased. At lower angles (45°-60°), the surface damage was characterized by a mixed-mode mechanism involving plastic ploughing and brittle micro-cracking. In contrast, at higher angles (75°-90°), the mechanism shifted towards surface compaction and delamination, primarily driven by particle embedding. The CFD simulations corroborated the experimental trends, confirming a positive correlation between inlet pressure and erosion rate. Furthermore, the simulations indicated that both particle size and particle sphericity exhibited a negative correlation with the erosion rate. It is concluded that the erosion mechanism of WCB material exhibits a typical ductile-to-brittle transition with the increasing impact angle, with brittle spalling becoming the predominant failure mode under normal (90°) impact conditions. The recalibrated erosion rate equation demonstrates high predictive accuracy, with the CFD simulation results showing excellent agreement with the experimental data. These findings provide valuable insights into the erosion behavior of valve materials and offer a reliable theoretical basis for the optimization of anti-erosion designs in shale gas production systems.

导出引用

石维渺, 程金亮, 肖杰, 周念涛, 卢俊安, 黄玖辉, 何龙, 林元华. WCB阀门材料气固冲蚀实验与模拟研究[J]. 表面技术. 2026, 55(11): 183-195

SHI Weimiao, CHENG Jinliang, XIAO Jie, ZHOU Niantao, LU Jun'an, HUANG Jiuhui, HE Long, LIN Yuanhua. Experimental and Simulation Study on Gas-Solid Erosion of WCB Valve Materials[J]. Surface Technology. 2026, 55(11): 183-195

中图分类号： TG174

参考文献

[1] 陈新军, 刘曾勤, 申宝剑, 等. 深层煤层气勘探开发标准体系建设思考及实施战略探讨[J]. 煤田地质与勘探, 2025, 53(4): 74-85.
CHEN X J, LIU Z Q, SHEN B J, et al.Reflections and Implementation Strategies for Constructing a Standard System for Deep Coalbed Methane Exploration and Exploitation[J]. Coal Geology & Exploration, 2025, 53(4): 74-85.
[2] 李海, 郑马嘉, 赵文韬, 等. 页岩气压后返排油嘴动态调整技术应用及效果评价——以蜀南地区Z201区块H62平台为例[J]. 石油地质与工程, 2025, 39(1): 13-20.
LI H, ZHENG M J, ZHAO W T, et al.Application and Effectiveness Evaluation of Dynamic Adjustment Technology for Shale Gas Pressure Flowback Nozzle: A Case Study of the H62 Platform of Z201 Block in Southern Sichuan[J]. Petroleum Geology and Engineering, 2025, 39(1): 13-20.
[3] 刘永. 海相富有机质页岩渗吸机理研究[D]. 北京: 中国地质大学(北京), 2023.
LIU Y.Study on Imbibition Mechanism of Marine Organic- Rich Shale[D]. Beijing: China University of Geosciences, 2023.
[4] 朱苏阳, 彭真, 邸云婷, 等. 页岩气产能评价研究进展: 内涵、方法和方向[J]. 油气藏评价与开发, 2025, 15(3): 488-499.
ZHU S Y, PENG Z, DI Y T, et al.Research Progress on Shale Gas Productivity Evaluation: Concepts, Methods and Future Directions[J]. Petroleum Reservoir Evaluation and Development, 2025, 15(3): 488-499.
[5] 张鼎, 闫怡帆. 东胜气田冬季泡排剂制度确定及影响因素研究[J]. 广州化工, 2025, 53(7): 197-199.
ZHANG D, YAN Y F.Study on Determination and Influencing Factors of Winter Foaming and Discharging Agent System in Dongsheng Gas Field[J]. Guangzhou Chemical Industry, 2025, 53(7): 197-199.
[6] 商翼. 压裂作业过程风险分析与安全对策[J]. 安全、健康和环境, 2020, 20(7): 49-52.
SHANG Y.Risk Analysis and Safety Countermeasures in Fracturing Operation[J]. Safety Health & Environment, 2020, 20(7): 49-52.
[7] 朱筱敏, 陈贺贺, 谈明轩, 等. 从太平洋到喜马拉雅的沉积学新航程——21届国际沉积学大会研究热点分析[J]. 沉积学报, 2023, 41(1): 126-149.
ZHU X M, CHEN H H, TAN M X, et al.A New Journey in Sedimentology from the Pacific to the Himalayas: Analysis of Research Hotpots from the 21st International Sedimentological Congress[J]. Acta Sedimentologica Sinica, 2023, 41(1): 126-149.
[8] 邹才能, 杨智, 何东博, 等. 常规-非常规天然气理论、技术及前景[J]. 石油勘探与开发, 2018, 45(4): 575-587.
ZOU C N, YANG Z, HE D B, et al.Theory, Technology and Prospects of Conventional and Unconventional Natural Gas[J]. Petroleum Exploration and Development, 2018, 45(4): 575-587.
[9] 马新华. 非常规天然气“极限动用”开发理论与实践[J]. 石油勘探与开发, 2021, 48(2): 326-336.
MA X H."Extreme Utilization" Development Theory of Unconventional Natural Gas[J]. Petroleum Exploration and Development, 2021, 48(2): 326-336.
[10] 郭旭升, 周德华, 赵培荣, 等. 鄂尔多斯盆地石炭系-二叠系煤系非常规天然气勘探开发进展与攻关方向[J]. 石油与天然气地质, 2022, 43(5): 1013-1023.
GUO X S, ZHOU D H, ZHAO P R, et al.Progresses and Directions of Unconventional Natural Gas Exploration and Development in the Carboniferous-Permian Coal Measure strata, Ordos Basin[J]. Oil & Gas Geology, 2022, 43(5): 1013-1023.
[11] 郭彤楼, 熊亮, 叶素娟, 等. 输导层(体)非常规天然气勘探理论与实践——四川盆地新类型页岩气与致密砂岩气突破的启示[J]. 石油勘探与开发, 2023, 50(1): 24-37.
GUO T L, XIONG L, YE S J, et al.Theory and Practice of Unconventional Gas Exploration in Carrier Beds: Insight from the Breakthrough of New Type of Shale Gas and Tight Gas in Sichuan Basin, SW China[J]. Petroleum Exploration and Development, 2023, 50(1): 24-37.
[12] 天工. 常规、非常规天然气并重打开四川盆地发展空间[J]. 天然气工业, 2020, 40(1): 140.
TIAN G.Conventional and Unconventional Natural Gas Re-Opens the Development Space of Sichuan Basin[J]. Natural Gas Industry, 2020, 40(1): 140.
[13] 苏荆攀, 李永喜, 李华贵, 等. 多相流输送球阀内部气液固多相介质流动分析[J]. 阀门, 2022(6): 452-454.
SU J P, LI Y X, LI H G, et al.Analysis of Gas-Liquid- Solid Multiphase Medium Flow in Multiphase Conveying Ball Valve[J]. Chinese Journal of Valve, 2022(6): 452-454.
[14] 刘恩斌, 李茜, 寇博, 等. 页岩气分离器阀套式排污阀冲蚀特性研究[J]. 中国安全科学学报, 2024, 34(5): 52-60.
LIU E B, LI X, KOU B, et al.Study on Erosion Characteristics of Valve Sleeve Blowdown Valve of Shale Gas Separator[J]. China Safety Science Journal, 2024, 34(5): 52-60.
[15] 邢树宾, 陈瑶瑶, 杨乐乐, 等. 基于气液分离的天然气双入口优化设计[J]. 天然气工业, 2023, 43(2): 114-120.
XING S B, CHEN Y Y, YANG L L, et al.Design Optimization of Natural Gas Double Inlets Based on Gas-Liquid Separation[J]. Natural Gas Industry, 2023, 43(2): 114-120.
[16] 乔元, 仇畅, 钱锦远, 等. 笼式调节阀的冲蚀磨损与空蚀[J]. 化工进展, 2023, 42(10): 5111-5120.
QIAO Y, QIU C, QIAN J Y, et al.Analysis of Erosion and Cavitation Wear in the Cage-Typed Control Valve[J]. Chemical Industry and Engineering Progress, 2023, 42(10): 5111-5120.
[17] 刘良果, 刘力升, 梅茜迪. 输气站场分离器排污阀内漏相关问题探讨[J]. 科技创新导报, 2019, 16(22): 110-112.
LIU L G, LIU L S, MEI X D.Discussion on Internal Leakage of Drain Valve of Separator in Gas Transmission Station[J]. Science and Technology Innovation Herald, 2019, 16(22): 110-112.
[18] 刘明颢, 刘旭煜, 上官杨沁, 等. 串联弯管间距对弯管冲蚀磨损影响的数值模拟[J]. 科学技术与工程, 2025, 25(16): 6707-6716.
LIU M H, LIU X Y, SHANGGUAN Y Q, et al.Numerical Simulation of Effect of Series Elbow Spacing on Erosion Wear of Elbow[J]. Science Technology and Engineering, 2025, 25(16): 6707-6716.
[19] 郭华锋, 朱聪聪, 赵恩兰, 等. 基于正交试验的超音速火焰喷涂WC-¹²Co涂层抗冲蚀性能研究[J]. 排灌机械工程学报, 2022, 40(4): 419-426.
GUO H F, ZHU C C, ZHAO E L, et al.Study on Erosion Wear Resistance of HVOF-Sprayed WC-¹²Co Coating Based on Taguchi Method[J]. Journal of Drainage and Irrigation Machinery Engineering, 2022, 40(4): 419-426.
[20] 邓宽海, 程金亮, 林元华, 等. 基于气-固两相流喷嘴实验的20G钢冲蚀机理研究[J]. 表面技术, 2024, 53(17): 50-61.
DENG K H, CHENG J L, LIN Y H, et al.Erosion Mechanism of 20G Steel Based on Gas-Solid Two-Phase Flow Nozzle Experiment[J]. Surface Technology, 2024, 53(17): 50-61.
[21] 廖柯熹, 钟瀚宇, 何国玺, 等. 气井口固定式节流阀固体颗粒冲蚀行为的数值模拟[J]. 腐蚀与防护, 2025, 46(3): 77-83.
LIAO K X, ZHONG H Y, HE G X, et al.Numerical Simulation of Solid Particle Erosion Behavior in Fixed Throttle Valve at Gas Well Head[J]. Corrosion and Protection, 2025, 46(3): 77-83.
[22] LIAO K X, ZHONG H Y, HE G X, et al.Numerical Simulation of the Erosion Behavior of Solid Particles in Fixed Throttle Valves at Gas Wellheads[J]. Corrosion & Protection, 2025, 46(3): 77-83.
[23] 钟林, 冯桂弘, 张计春, 等. 基于CFD数值模拟的排污阀冲蚀磨损影响规律[J]. 排灌机械工程学报, 2021, 39(2): 151-157.
ZHONG L, FENG G H, ZHANG J C, et al.Influence Law of Erosion Wear of Blowdown Valve Based on CFD Numerical Simulation[J]. Journal of Drainage and Irrigation Machinery Engineering, 2021, 39(2): 151-157.
[24] LIN Z, SUN X W, YU T C, et al.Gas-Solid Two-Phase Flow and Erosion Calculation of Gate Valve Based on the CFD-DEM Model[J]. Powder Technology, 2020, 366: 395-407.
[25] XU B L, LIN Z, ZHU Z C, et al.Experimental and Simulation Study of the Effect of Gravity on the Solid- Liquid Two-Phase Flow and Erosion of Ball Valve[J]. Advanced Powder Technology, 2022, 33(2): 103416.
[26] American Society for Testing and Materials. Standard Test Method for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets[S]. ASTM G76-18, 2018.
[27] 金河, 刘涛, 杜萍, 等. 基于边折叠的实景三维模型简化算法[J]. 地球信息科学学报, 2024, 26(10): 2254-2267.
JIN H, LIU T, DU P, et al.Mesh Simplification Algorithm for Photorealistic 3D Models Based on Edge Collapse[J]. Journal of Geo-Information Science, 2024, 26(10): 2254-2267.
[28] LIU M Y, JIANG C, KHOO B C, et al.A Cell-Based Smoothed Finite Element Model for the Analysis of Turbulent Flow Using Realizable K-ε Model and Mixed Meshes[J]. Journal of Computational Physics, 2024, 501: 112783.
[29] NGUYEN V T, SAGAR H J, EL MOCTAR O, et al.Understanding Cavitation Bubble Collapse and Rebound near a Solid Wall[J]. International Journal of Mechanical Sciences, 2024, 278: 109473.
[30] 汪军, 徐金明, 龚明权, 等. 基于扫描电镜图像和微观渗流模型的云冈石窟砂岩风化特征分析[J]. 水文地质工程地质, 2021, 48(6): 122-130.
WANG J, XU J M, GONG M Q, et al.Investigating Weathering Features of Sandstones in the Yungang Grottoes Based on SEM Images and Micro-Scale Flow Model[J]. Hydrogeology & Engineering Geology, 2021, 48(6): 122-130.
[31] 董正琼, 黄贤文, 徐仁, 等. 基于四波横向剪切干涉的表面形貌测量方法[J]. 激光技术, 2024, 48(6): 906-912.
DONG Z Q, HUANG X W, XU R, et al.Measurement Method for Surface Topography Based on Quadriwave Lateral Shearing Interferometry[J]. Laser Technology, 2024, 48(6): 906-912.
[32] 王国涛, 朱丽云, 刘岑凡, 等. 基于试验和CFD模拟的稠油热采井口四通管冲蚀规律分析[J]. 表面技术, 2021, 50(8): 247-256.
WANG G T, ZHU L Y, LIU C F, et al.Analysis of Erosion Law of Four-Way Pipe in Heavy Oil Thermal Production Wellhead Based on Experiment and CFD Simulation[J]. Surface Technology, 2021, 50(8): 247-256.
[33] 张林, 刘刚, 曾东, 等. 超高速激光熔覆Stellite 6涂层的抗汽蚀及冲蚀性能[J]. 表面技术, 2022, 51(4): 167-175.
ZHANG L, LIU G, ZENG D, et al.Anti-Cavitation and Erosion Resistance of Stellite 6 Coating by Ultra-High Speed Laser Cladding[J]. Surface Technology, 2022, 51(4): 167-175.
[34] 崔璐, 杨栩卿, 李佳望, 等. QT1100连续油管钢的抗液固两相流冲蚀性能[J]. 机械工程材料, 2024, 48(11): 55-60.
CUI L, YANG X Q, LI J W, et al.Erosion Resistance of QT1100 Coiled Tubing Steel in Liquid-Solid Two-Phase Flow[J]. Materials for Mechanical Engineering, 2024, 48(11): 55-60.
[35] 牛永生, 田伟华. 牵引传动试验方法的归纳和对比研究[J]. 机械传动, 2009, 33(6): 106-107.
NIU Y S, TIAN W H.Induction and Comparative Study on the Test Methods of Traction Drive[J]. Journal of Mechanical Transmission, 2009, 33(6): 106-107.
[36] 敬佩瑜, 郑思佳, 程华, 等. 配气站浮动式球阀阀芯迎流面冲蚀行为及其后果[J]. 流体机械, 2024, 52(3): 73-80.
JING P Y, ZHENG S J, CHENG H, et al.Erosion Behavior and It’s Consequences of Valve Core Incoming Surface for Floating Ball Valve in Gas Distribution Station[J]. Fluid Machinery, 2024, 52(3): 73-80.
[37] 刘会鹏, 杨闻, 邰燕翔, 等. 圆盘涡轮搅拌器的气液混合特性CFD分析[J]. 化学工程, 2025, 53(4): 43-47.
LIU H P, YANG W, TAI Y X, et al.CFD Analysis of Gas-Liquid Mixing Characteristics of Disc Turbine Agitator[J]. Chemical Engineering, 2025, 53(4): 43-47.
[38] 何豪杰, 张祖提, 姚伍平, 等. 密闭容器清吹过程流场及噪声特性数值模拟与优化研究[J]. 振动与冲击, 2025, 44(2): 333-343.
HE H J, ZHANG Z T, YAO W P, et al.Numerical Simulation and Optimization of Flow Field and Noise Characteristics in the Blowing Process of a Confined Vessel[J]. Journal of Vibration and Shock, 2025, 44(2): 333-343.
[39] 彭世昌, 刘美丽, 白春禄, 等. 网格类型对水力旋流器内湍流模拟的适应性分析[J]. 石油学报(石油加工), 2023, 39(3): 599-610.
PENG S C, LIU M L, BAI C L, et al.Analysis of Adaptability of Mesh Type to Turbulence Simulation in Hydrocyclones[J]. Acta Petrolei Sinica (Petroleum Processing Section), 2023, 39(3): 599-610.
[40] 张子龙, 周鸿翔, 王进卿, 等. 液固流异径管弯管连接管路冲蚀磨损研究[J]. 石油机械, 2025, 53(3): 123-131.
ZHANG Z L, ZHOU H X, WANG J Q, et al.Erosion Wear of Reducing Pipe/Elbow Connecting Pipeline in Liquid-Solid Flow[J]. China Petroleum Machinery, 2025, 53(3): 123-131.