Papers by Keyword: Slurry Erosion

Abstract: Additive manufacturing (AM) has revolutionized complex component fabrication. Wire arc additive manufacturing (WAAM) uses an electric arc to deposit material layers, offering cost-effectiveness and speed. Inconel-625, known for its wear resistance, is widely used in marine and high-performance applications. This study examines post-heat treatment effects on WAAM-fabricated Inconel-625's slurry erosion behavior. WAAM deposits Inconel-625 layer by layer, characterized for microstructure and mechanical properties. Controlled post-heat treatments at 1100°C for 2 hours (water quenched, furnace cooled) enhance material properties. Specimens undergo slurry erosion tests under varied conditions: impact velocity (20, 30, 40 m/s) and strike angle (30, 60, 90°). Results show improved wear resistance with water quenching at 1100°C, while erosion intensifies with higher impact velocities. The influence of strike angle on slurry erosion varies between treated and untreated specimens. FESEM imaging reveals erosion mechanisms, with ductile failure at lower strike angles for as-built WAAMed Inconel 625, contrasting with brittle failure post-water quenching at 1100°C. This study informs engineers and designers aiming to enhance AM component performance in erosive environments, contributing to understanding manufacturing processes, heat treatment, and material performance in additive manufacturing.

Abstract: Slurry erosion is a major concern in marine components which are subjected to wear and corrosion. These problems are addressed by developing materials which are harder and possessing excellent corrosion resistance in sea water. In this regard, there are serious attempts to modify the existing surfaces or developing new composite materials which are hard and also possess good strength. There are few reports suggesting the improved slurry erosion resistance of aluminium alloy by dispersing SiC within the metallic matrix. Higher the extent of SiC in the matrix material, better will be the slurry erosion resistant. In the light of above, the present work will focus on innovative development of Al6061-SiC composites by the combined process of powder metallurgy and casting followed by hot extrusion. A maximum amount of 40 wt % of SiC has been successfully incorporated in the hot extruded composites. The hot extruded composites are subjected to slurry erosive wear test in 3.5% NaCl solution containing silica sand particles. The parameters such as slurry concentration, rotational speed used in the present study are 10-30g/l, 500 – 1000 rpm respectively with test duration maintained at 24 hr. It is observed that increased content of SiC in matrix alloy has resulted in significant improvement in the slurry erosion resistance of the developed composites.

Abstract: Erosive wear is one of the major failure modes in metal and plastic injection moulding. Certain regions such as gate, runner and some areas on the cavity wall, are particularly susceptible to erosive wear damage, leading to the reduction in the mould lifetime. Several parameters such as pressure, injection velocity, melting temperature, including various contaminants during material processing, have influenced to decrease the surface quality of the mould. Hence, the wear test and prediction are necessary information for the life extension of the mould material, and were carried out in present work. This work therefore aims to determine slurry erosion wear behaviour of the mould material, and presents a new semi-empirical approach to estimate the wear coefficient of material itself as a function of impact angles via an erosion test apparatus. It was found that the maximum wear coefficient of the tool material is around ~ 2.51 x 10^-7 at the impact angle of 60^o. While that the minimum value was found to be ~ 4.70 x 10^-8 at the angle of impingement of 30^o. Therefore, the effect of the different angle of impact on the impact energy, can also represent the failure modes in the tool steel material as ductile failures.

Abstract: In the present work, effect of various heat treatments on slurry erosion behavior of 13Cr-4Ni martensitic stainless steel (MSS) at different impingement angles has been studied. The as-received cast bars of MSS were given various heat treatments. These heat treatments involved the austenitization of cast steel at temperatures of 950° C, 1000° C and 1050° C for different soaking durations of 2, 4 and 6 h at each temperature. This was followed by oil quenching then tempering for 1 h at a 600° C air cooled. Heat treated MSS samples were characterized for microstructure and mechanical properties viz. hardness, ductility (% elongation), tensile strength (UTS), and toughness. For wear characterization, slurry erosion tests were conducted at different impingement angles for as-received cast and heat treated samples. The heat treated MSS shows approximately 34% lesser weight loss as compared to as-received cast MSS. Increase in toughness of heat treated samples is found to be responsible for the improved slurry erosion resistance. Impingement angle close to 0° showed least wear loss.