Papers by Keyword: Erosive Wear

Abstract: This study investigated the influence of nickel (Ni) addition on erosive wear property of multi-component white cast iron with good erosive wear resistance. Multi-component white cast irons (MWCIs) with 2 mass % of carbon (C), 5 mass % of chromium (Cr), molybdenum (Mo), tungsten (W), niobium (Nb) and 0, 3, 5 mass % of Ni were prepared as experimental materials. The heat treatment condition was quenching by forced air cooling after keeping the specimens at 1123K for 3.6ks. Specimens with size of 50mm×50mm×10mm were tested using a suction-type blasting machine. The test was conducted with impact angle of 30, 60 and 90 deg. at room temperature. Collision particles were irregular steel grids with average particle diameter of 770μm and hardness of 810HV1. The speed of air flow was about 100m/s while the speed of impact particles was around 20.0g/s and the total time of each experiment was 3600 sec.. According to the result, erosion rate was decreased with the increase of Ni content in all of the impact angles. Especially, MWCIs which contain 5 mass % Ni showed the most excellent erosive wear resistance. As reasons, it can be considered that with Ni addition, the volume fraction of eutectic carbides and secondary carbides was increased which enhanced the matrix structure and suppressed the surface deformation of the experimental surface. Therefore, the increasing of eutectic carbides and secondary carbides can be considered as the reason of erosive wear resistance increased.

Abstract: This paper investigates erosive wear properties of carbon-epoxy polymer composites. Hand layup technique was employed to fabricate the composite specimens. Sand erosion properties of carbon/epoxy polymer composites were examined by changing testing parameters such as varying angle of impact (30⁰,45⁰,60⁰ and 90⁰), velocity of impact of sand particles (48m/s and 70m/s) and Stand-Off distance (5mm and10mm); and also by changing composite processing parameters such as fiber volume (20%, 25%, and 30%) and fiber orientation (30⁰,60⁰ and 90⁰). Irrespective of fiber volume and fiber orientation, rate of erosion shows increasing tendency, with increase of impact velocity. It was observed that with increase in fiber volume, erosion rate increases and where fiber orientation is concerned, increase of fiber orientation leads to increase in erosion rate. Irrespective of fiber orientation and fiber volume, Increase of Stand-Off distance leads to decrease in erosion rate. Finally the eroded surface morphology was observed by using SEM.

Abstract: One of the problems encountered in heat exchangers working at high temperatures is the degradation caused by erosive processes, especially in coal-fired power plants. One of the factors that contribute to the degradation of the material is the microstructural changes, like the spheroidization of the carbides. This reduces the mechanical strength of the material and consequently accelerates its wear process. The objective of this work was to evaluate the effect of spheroidization under erosive wear conditions on ASTM A106 steel. The samples were submitted to different treatment times and temperatures, aiming to generate spheroidization in the samples, later submitted to erosive wear tests. Loss of mass, microstructures and mechanical strength were evaluated from the microhardness, with the evolution of the spheroidization process. The samples with higher level of spheroidization, obtained in the temperatures of 730 ° C in times above 50 hours presented greater reduction of hardness that resulted in greater losses of mass. In general, with the increase of spheroidization, there is reduction of mechanical resistance and erosive erosion, but with a gradual reduction in wear rate. This is possibly due to the increased ductility / toughness of the matrix, which delays the process of debris formation on the ASTM A106 steel surface during the hot erosive process.

Abstract: The erosive wear resistance of manual arc welded hardfacings with low-carbon or stainless steel matrix, varied WC grain size (0.23-0.61 mm) and varied WC content (max. 40 wt. %) was studied. Electrodes were produced by JSC “Anykščių varis“ company (Lithuania). Testing was performed according to GOST 23.201-78 standard using the Centrifugal Accelerator of Kleis (CAK). Test parameters were as following: room temperature; silica sand with particles size 0-0.6 mm; particle impact velocity – 10, 30, 50 and 80 ms-1; impact angles – 30° and 90°.It was found that there is only minor (usually not more than 2 times) effect of WC grain size and content on erosive wear of studied hardfacings. There is strong effect of velocity on wear rate. The graph showing the effect of abrasive particle‘s kinetic energy on wear rate is provided. It was found that the wear rate increases 2.8 times faster than kinetic energy of abrasive particles. The wear resistance of coatings could be improved by addition of WC when hardfacing is tested with impact angle of 30°. However, for impact angle of 90° the addition of WC into hardfacing has no effect or is even detrimental (leading to the increase in wear rate). The hardfacings with WC grain size in the range from 0.14 to 0.27 mm have the lowest wear rates during testing with impact angle of 30°. A discussion of the wear mechanisms for the hardfacings is provided, based on data and observations obtained by using scanning electron microscopy.

Abstract: A nodular cast iron (NCI) has been surface melted using the high power direct diode laser (HPDDL) with a quasi-rectangular laser beam spot and the uniform distribution of power. The effect of a heat input and a shielding gas on the quality of surface melted layers (SMLs) has been investigated. The microstructure of the SMLs has been assessed by optical microscopy, scanning electron microscopy and X-ray diffraction (XRD). Comparative erosion tests between the SMLs and as-received NCI have been performed following the ASTM G 76 standard test method. The HPDD laser surface melting of the NCI enables to produce non-porous layers having a hardness up to 1000 HV. It has been determined that the hardness of SMLs depends on the amount of cementite and residual austenite in the fusion zone. The SMLs produced in an argon atmosphere contain higher volume fraction of austenite, than those produced in nitrogen, and consequently have the lower hardness. With increasing heat input the hardness increases, as the result of more complete dissolution of graphite and the higher amount of cementite. The SMLs exhibited significantly higher erosion resistance than the as-received NCI for erodent impact angle of 30°, and slightly lower at 90°.

Abstract: Metal matrix composite layers were fabricated on AISI 304L substrate by diode laser surface alloying with direct injection of chromium carbide Cr₃C₂ powder into the molten-pool. The influence of laser alloying parameters on the quality of the alloyed layers were investigated. The alloyed layers were examined by optical metallography and scanning electron microscopy. Comparative erosion tests between the AISI 304L substrate and the alloyed layers have been performed following the ASTM G 76 standard test method. The uniform laser beam intensity profile of the laser used ensures to produce fully dense alloying layers with homogenous distribution of Cr₃C₂ particle throughout the matrix alloy. Distribution and dissolution of Cr₃C₂ particles are strongly dependent on the laser power level. The alloyed layers exhited noticeable increased erosion resistance in comparison to AISI 304L substrate for both 30° and 90° impact angles.

Abstract: Erosive wear is defined as material loss from surface due to impact of liquid and solid particles. This mechanism can be seen widely in the industry such in mining, valves, pipe and pump systems. Characteristics and wear amount of erosive wear is affected by different parameters like geometry, impact speed, impingement angle of the hard particles, solid-liquid rate, material hardness and toughness. To determine the effect of these parameters on erosive wear, a wear slurry tank is designed. Before the prototype design of the test tank, different geometrical parameters of the tank are analyzed using simulation software. By computational investigations, the 3-D flow in a liquid/solid (slurry) tank is established and analyzed. Aim of the mathematical analysis was to detect the effect of the tank design parameters on liquid impact velocity and distribution on the test specimen surface. According to the results, geometrical parameters of the tank such as; baffle width, propeller length, assembly position of the specimens in the slurry tank, the distance between the propeller and specimens are defined.

Abstract: One of the areas in which increased durability is of particular significance is the use of machine elements in conditions of intensive exposure to erosive wear, for example, turbine blades of aircraft engines and power turbines in ventilation systems, and machine elements working in a dusty environment. As it is apparent from the analysis of the state of the art, high possibilities to increase the erosive and abrasive wear resistance of machine elements are created by appropriately designed coatings and layers, especially multilayer coatings composed on the base of materials with different plasticity properties. This is associated with particular characteristics of this type of multilayer coatings that allow the absorption of external energy reaching the surface without causing permanent damage to the coating, while significantly reducing the erosive wear rate.The article presents the results of material research and the results of erosion test of three different materials solutions of surface engineering, i.e. multilayer coatings (Cr / CrN) x8, (TiN / ZrN)_multinano and a (Ti-Al) _{intermetallic} / AlCrTiN hybrid layer, obtained on titanium alloy Ti6Al4V. The (Cr / CrN) x8 and (TiN / ZrN)_multinano multilayer coatings were obtained by arc evaporation, and the (Ti-Al) _{intermetallic} / AlCrTiN hybrid layer was prepared using a hybrid technology combining diffusion saturation in aluminium powders and arc evaporation in a single technological process. The selected material solutions of the surface layer were subjected to the analysis of the structure by scanning electron microscopy (Hitachi 3000). Measurements of hardness and Young's modulus were conducted using the nanohardness Tester CSM. The results of this study allowed the authors to compare the erosive wear resistance and wear resistance of selected material solutions, and this led to the conclusion that the (Ti-Al) _{intermetallic} / AlCrTiN hybrid layer is the most effective solution.

Abstract: The paper presents the numerical analysis of erosive wear on the guide vanes of a Francis turbine using CFD code. The 3-D turbulent particulate-liquid two-phase flow equations are employed in this study. The computing domain is discretized with a full three-dimensional mesh system of unstructured tetrahedral shapes. The finite volume method is used to solve the governing equations and the pressure-velocity coupling is handled via a Pressure Implicit with Splitting of Operators (PISO) procedure. Simulation results have shown that the volume fraction of sand at the top of the guide vanes is higher than others and the maximum of volume fraction of sand is at same location with the maximum of sand erosion rate density. The erosive wear is more serious at the top of the guide vanes.

Abstract: Elbow as common components in the gas pipeline fails easily to natural gas carrying solid particle erosion in the process of practical work. From the viewpoint of hydromechanics, the paper analyses the flow field distribution of manifold pressure and gas-solid trajectory by using the Gambit model and Fluent software in view of the right-angle elbow and numerical simulation of the adjacent manifold. The result obtains the situation about the manifold inner wall by the solid particle erosion wear. The simulation results show more intuitively the elbow, the most prone to erosion part in the manifold adjacent area and shape in erosion. Meanwhile, the paper analyses the factors affecting the occurrence and development of erosion.