Abrasive wear of engineering materials by mineral and industrial wastes

Abstract

Abrasive wear damage in eight engineering materials was evaluated through a statistically designed experiment in a laboratory model hard rubber disk wear testing machine. Mineral and industrial wastes were used as abrasives incorporated in different media and at two concentrations. Wear rate, coefficient of friction and specimen temperature rise were correlated with material, abrasive, medium and abrasive concentration. The abrasive particle size and shape and worn specimen surface characteristics were analyzed by scanning electron microscopy. Alumina, followed by silica sand and iron ore, is the most aggressive mineral in increasing wear rate. The least abrasive mineral is limestone, with red mud as a close second. Quantitatively, silica sand wears all materials 100 times faster than limestone. Similarly, fly ash and iron ore wear all materials 2.2 and 4.2 times faster, respectively, than coke breeze. Tool steel wears the least, with chromium plated steel wearing 2.5 times faster than tool steel. Mild steel wears 2.5 times faster than cast iron with maraging steel falling between them. The different media have no effect on wear rate. The 50% concentration of abrasive increased wear rate by a factor of 5 over 10% concentration. Mild steel generates twice the coefficient of friction μ over tool steel and 25% more over cast iron. Silica sand increases μ by 61% over coke breeze. Water generates a 67% increase in μ over high viscosity oil. Acidic water increases μ by 7% over neutral water but produces a 50% less temperature rise. Bronze increases μ by 17% and temperature by 38% over cast iron.