Abrasive Water Jet Research Articles

Insights of Abrasive Water Jet Slotting on Enhancing Efficiency of Hydraulic Fracturing

Insights of Abrasive Water Jet Slotting on Enhancing Efficiency of Hydraulic Fracturing

Magnesium Alloy and Silicon Nitrides Composite Study: Synthesis and Abrasive Water Jet Machining Behavior and Optimization

<div>Related to traditional engineering materials, magnesium alloy-based composites have the potential for automobile applications and exhibit superior specific mechanical behavior. This study aims to synthesize the magnesium alloy (AZ61) composite configured with 0 wt%, 4 wt%, 8 wt%, and 12 wt% of silicon nitride micron particles, developed through a two-step stir-casting process under an argon environment. The synthesized cast AZ61 alloy matrix and its alloy embedded with 4 wt%, 8 wt%, and 12 wt% of Si<sub>3</sub>N<sub>4</sub> are subjected to an abrasive water jet drilling/machining (AJWM) process under varied input sources such as the diameter of the drill (D), transverse speed rate (v), and composition of AZ61 composite sample. Influences of AJWM input sources on metal removal rate (MRR) and surface roughness (Ra) are calculated for identifying the optimum input source factors to attain the best output responses like maximum MRR and minimum Ra via analysis of variant (ANOVA) Taguchi route with L16 design approach. The ANOVA analysis revealed that D, v and the composition of AZ61 alloy composite contribute 26.45%, 16.28%, and 20.84%, respectively, to the output response conditions for higher MRR. Additionally, design 7 exhibits a high MRR of 0.017 g/s and a surface roughness (Ra) of 0.84 μm. The optimum AWJM input source of design 7 is proposed for industries to mass production applications.</div>

COMPARISON OF CHOSEN METAHEURISTIC ALGORITHMS FOR THE OPTIMIZATION OF THE ABRASIVE WATER JET TREATMENT PROCESS

Abrasive waterjet machining (AWJ) is characterized by significantly better efficiency and better precision for difficult-to-machine materials than conventional machining technologies. However, the larger number of control parameters characterizing this process needs optimization. The study compares the performance of three nature-inspired metaheuristic algorithms, ALO, GWO, and MFO for optimizing the abrasive water jet (AWJ) treatment. The Response Surface Methodology was used to determine the cost function. The study evaluates the convergence and computational cost of the algorithms to aid future developments in this field. The study aims to maximize the cutting thickness by predicting the optimal water-abrasive cutting parameters (nozzle diameter, abrasive concentration, feed speed). For all three algorithms, the maximum cutting depth was determined to be 87.47 mm, which differs only less than 3% from the actual value. The results highlight the potential of ant-lion optimization (ALO), grey wolf optimizer (GWO), and (MFO) moth-flame optimization algorithms for resolving optimization issues in AWJ machining.

Effect of abrasive volume fraction on energy utilization in suspension abrasive water jets based on VOF-DEM method

Suspension abrasive water jets (AWJs) rock breaking is the kinetic energy of abrasive particle group transport and transfer. However, it is difficult to be popularized and utilized due to the high energy consumption of rock breaking. In this study, the energy transfer rate in AWJs was focused on and was investigated using numerical and experimental methods. A two-way coupled algorithm was used to reproduce the oscillation characteristics of abrasive jets velocities, indicating that not only the abrasives' velocities but also the abrasives' distribution is crucial in energy transfer rate. Different dominant factors accounting for the abrasives' velocities and distribution were identified, and two parameters were proposed to account for the energy transfer process during the jet evolution process. The optimum abrasives' volume fraction was determined based on the evolution of the energy density and ratio of abrasive kinetic energy to the total energy, which was validated by rock breaking experiments. Increasing ratio of abrasive kinetic energy to the total energy by using the method of changing the volume fraction of the abrasive is an effective method to improve the rock breaking efficiency of suspension abrasive water jets.

Hole drilling in basalt-reinforced sustainable composites using abrasive waterjet for construction applications

This study aimed to develop, characterize, and optimize abrasive waterjet (AWJ) machining of sustainable basalt fiber-reinforced polymer composites for construction and industrial applications. Dynamic mechanical analysis, thermogravimetric analysis, and X-ray diffraction revealed enhanced thermal stability, increased decomposition temperatures, and improved crystallinity, correlating with improved tensile strength of developed composites. To address drilling-induced damage that can compromise long-term quality and applicability, AWJ drilling parameters were optimized to minimize damage while enhancing material removal rates. A novel quantification method for entry total surface damage (ETD) was implemented to assess machining defects. Results showed that standoff distance significantly influences ETD and exit delamination, while higher water pressure reduces entry damage. Abrasive flow rate primarily affected the material removal rate. FE-SEM analysis revealed microstructural changes in drilled surfaces, including damage zones and matrix fractures specific to AWJ processing. Multi-objective optimization using Genetic Algorithm is performed to enable flexible parameter selection and informed decision making, balancing machining efficiency and minimal damage.

Fragmentation characteristics of abrasive particles for hard rock drilling with waterjet energy parameter

The use of abrasive waterjets (AWJs) for rock drilling offers advantages in urbanized areas, locations that are vulnerable to damage, and piling operations. However, the overall operational cost of AWJ systems remains high compared to that of conventional drilling methods, which constrains the long-term industrial application of AWJs. For instance, the abrasive costs account for over 60% of the total process cost, but the recycling of abrasives remaining after drilling could significantly reduce machining costs. In this study, the post-impact characteristics of abrasives were explored, aiming to enhance their recyclability. The physical properties and particle distribution of used abrasives vary depending on the jet energy, ultimately affecting their recyclability and recycling rate. The particle properties of used abrasives (particle size distribution, particle shape, and mean particle size) were compared under different waterjet energy variables (standoff distance (SOD) and water pressure) and test conditions (dry and underwater). Furthermore, the collision stages of the abrasive particles within a waterjet system were classified and analyzed. The results revealed that abrasive fragmentation predominantly occurred due to internal collisions within the mixing chamber. In addition, an attempt was made to optimize the waterjet parameters for an economical and efficient operation. The findings of this study could contribute to enhancing the cost-effectiveness of AWJ systems for rock drilling applications.

Modeling eroded topography in masked abrasive slurry jet pocket milling

Abrasive slurry and water jets can be used together with erosion-resistant masks to rapidly machine micro-pockets. However, the use of masks can result in an undesirable erosion and mask under-etching which can locally increase the depth twofold or more in the vicinity of the mask edges. Although the detailed mechanisms leading to the undesirable erosion are not well understood, they appear to be related to the interaction of the jet flow with the mask edge. This paper employs novel experimental techniques and coupled computational fluid dynamics/surface evolution models to rigorously study these mechanisms for the first time. To demonstrate the techniques, the abrasive slurry jet micromachining of pockets into Al 6061-T6 using SS304 masks was considered, using a novel technique to precisely control the position of the abrasive slurry jet relative to the mask edge. The model reasonably accurately predicted the surface evolution and undesirable erosion in various scenarios, as well as the physics of mask under-etching. The position of the jet relative to the mask edge and the scanning direction were found to strongly affect the extent of undesirable erosion. The model suggests that the stagnation zone in masked milling is smaller than that in unmasked milling, and that this facilitates the formation of slurry recirculation zones near the mask edges which, together with particle ricochets off the mask edge, interact to create the undesirable erosion and under-etching. Based on this improved understanding, several path strategies were presented that were found to minimize the undesirable erosion and thus allow the milling of pockets with more uniform depths.

Mechanism and prevention of coal bursts in gob-side roadway floor under thick and hard roof in the deep mining area of Ordos

The complex stress environment in deep roadways, often exacerbated by thick and hard strata, frequently precipitates coal bursts, posing significant safety hazards. This paper investigates the mechanisms and preventive methods for coal bursts in the gob-side roadway floor (GSRF) under thick and hard roof in the Ordos region, China. First, the stress-distributing characters of GSRF were analyzed then a stress calculation formula was derived. A mechanical model was developed to determine the critical stress for buckling failure of the roadway floor strata. Criteria for the bursting instability of GSRF were then established. The lateral static load from the adjacent gob, the advancing static load from the working face, and the disturbance load from overlying thick and hard roof fractures combine to transmit high loads and energy to the roadway floor via the “roof → rib → floor” pathway, causing increased stress concentration and energy accumulation. When the conditions satisfy the criteria for bursting instability, coal bursts can occur on the roadway floor. To mitigate dynamic load disturbances, the paper proposes roof regional fracturing and abrasive water jet axial roof cutting. Hydraulic reaming of gutters in the roadway ribs and deep hole blasting at the roadway bottom corners are offered to alleviate the static loads on the surrounding rock. The implementation of targeted prevention measures for dynamic and static loads effectively reduces coal bursts in GSRF. These findings offer an example of preventing and controlling coal bursts in other mines of the Ordos region with comparable geological conditions.

Preliminary investigation on spent garnet as a novel supplementary cementitious material

The escalating global demand for cement, a fundamental material in infrastructure development, has exacerbated environmental challenges, particularly through significant carbon dioxide (CO₂) emissions, which account for approximately 8.3 % of global anthropogenic CO₂ output. This research explores the potential of spent garnet powder, a byproduct of abrasive water jet machining, as a sustainable supplementary cementitious material (SCM) to mitigate these impacts. The spent garnet powder, characterized by a high concentration of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), and iron oxide (Fe₂O₃), was subjected to rigorous analysis. X-ray Fluorescence (XRF) confirmed its chemical suitability for pozzolanic applications, while laser particle size analysis revealed a finer granulometry relative to Ordinary Portland Cement (OPC), which is advantageous for enhancing pozzolanic reactivity. Scanning Electron Microscopy (SEM) demonstrated the angular and irregular morphology of the garnet particles, which is conducive to improved interfacial bonding within the cement matrix. X-ray Diffraction (XRD) identified active mineral phases that are critical for promoting pozzolanic reactions, and Thermogravimetric Analysis (TGA) demonstrated the material’s superior thermal stability, with minimal decomposition at elevated temperatures. Fourier Transform Infrared Spectroscopy (FTIR) identified strong silicon-oxygen (Si-O) and aluminum-oxygen (Al-O) bond structures, indicative of robust pozzolanic potential. The Strength Activity Index (SAI) and Frattini tests further substantiated the pozzolanic activity, revealing that a 10 % replacement of OPC with SGP not only enhances compressive strength but also meets the stringent requirements of ASTM C618. Additionally, the economic analysis underscores the cost-effectiveness of utilizing spent garnet powder, presenting a viable strategy for reducing both production costs and CO₂ emissions in the cement industry. This study conclusively positions spent garnet powder as a highly promising supplementary cementitious material, with significant implications for advancing sustainable construction practices and reducing the environmental footprint of cement production.

Gradient nanostructure enabled exceptional fretting fatigue properties of Inconel 718 superalloy through submerged abrasive waterjet peening

Submerged Abrasive Waterjet Peening (SAWJP) shows great application potential in augmenting the fatigue properties of metallic parts. Thus, the present work aims to investigate the influence of SAWJP on the Surface Integrity (SI) and Fretting Fatigue (FF) properties of Inconel 718 (IN718) superalloy and illustrate the microstructural evolution, FF life improvement, and fretting wear mechanism. First, the SI of the IN718 specimen was examined following treatment via SAWJP. Results showed that the specimen subjected to SAWJP formed a total plastic deformation layer of 56 μm. The maximum microhardness and Compressive Residual Stress (CRS) measured across the depth of the SAWJP-treated specimens exhibited an increase in values ranging between 522 and 541 HV and 1171–1380 MPa, respectively. The FF test results of the specimen before and after SAWJP treatment at ambient temperatures indicated that the FF life of the SAWJP-treated specimen surpassed that of the as-received specimen by a factor of 2.81. The examination of the FF fracture, contact surface, and crack propagation behavior revealed the crucial factors contributing to the enhanced FF resistance of the IN718 specimen, including the gradient nanostructure characterized by ultra-refined grains, substantial CRS, and elevated microhardness, which were all induced by the SAWJP treatment.

An unresolved SPH-DEM model for simulation of ductile and brittle surface erosion by abrasive water-jet (AWJ) impact

The abrasive water-jet (AWJ) erosion process involves the complex interaction between fluid medium, abrasive particles and solid material, which brings great challenges to the establishment of numerical model. Because traditional grid-based methods are not suitable for the problems of local deformation and material removal, the meshfree method smoothed particle hydrodynamics (SPH), based on the unresolved coupling and the discrete element method (DEM), is adopted to establish the model for AWJ study. The fluid medium is treated as a weakly compressible viscous liquid, the solid material is treated as an elastic-plastic material, and the abrasives are treated as rigid bodies. The fluid and solid phases are discretized with SPH particles, and the abrasives are described with DEM particles. The Johnson-Cook (J-C) and Johnson-Holmquist-II (JH-2) constitutive models are used to describe the stress-strain behavior of ductile and brittle materials, respectively. The effectiveness of the numerical model is further verified by AWJ impact experiments. The plastic deformation and cumulative failure characteristics of ductile materials, and the crack formation and propagation characteristics of brittle materials are systematically analyzed. The results provide insight for the AWJ research and lay a foundation for investigation of other complex fluid-particle flow in a numerical way.

Experimental Investigation on the Effect of Masked Multiple Passes Abrasive Waterjet Machining Surface Texturing on Coefficient of Friction

The surface texturing method is popular because of its ability to improve surface properties, specifically surface functioning, and friction control. It is a common technique used on material surfaces to improve friction performance. Laser surface texturing is the popular choice; however, this method suffers drawbacks such as cracking, heat-affected zone, and generation of hazardous fumes. The Abrasive Water Jet Machining (AWJM) was chosen is that, because the eroded material is carried by the waterjet, the process is clean and does not produce dust, chips, or chemical contaminants. This experiment examines the influence of AWJM and investigates how crater density and a multiple-pass machining path affect the stainless-steel friction characteristics when sliding in dry conditions. The texture was applied on the surface of stainless steel by masked multi-passes AWJM technique. According to the findings, there is less friction in craters with greater densities because there are more craters in the contact zone, which improves the trapping of debris particles and reduces friction, when the crater density rises from 4% to 18%, there is a greater chance of worn debris becoming trapped, which reduces friction. The coefficient of friction and crater roughness of the stainless-steel surface are all proportionally affected by the multiple-passes approach. The coefficient of friction increases with higher machining passes. There is more erosion and greater roughness when there are more jet passes. It is concluded that the masked multiple passes AWJM Surface Texturing technique has a significant impact on the Coefficient of Friction (COF).

Machining Efficiency and Property Change Analysis of Ti-6Al-4V Alloy Processed by Abrasive Water Jet Machining

Machining Efficiency and Property Change Analysis of Ti-6Al-4V Alloy Processed by Abrasive Water Jet Machining

Efficiency of machining polymer, marble and steel materials at abrasive water jet cutting

In recent decades, waterjet cutting technology has become widespread across various industries worldwide, ranging from automotive and insulation manufacturing to aerospace. Concurrently, it’s increasingly important for the applied technological parameters to be efficient and cost-effective. This necessitates the appropriate selection of key technological parameters. In this article, we examined the efficiency of abrasive waterjet cutting in three different material qualities: polymer, ceramic, and steel. The article explores the relationship between cutting depth—considered as one widely accepted indicator of efficiency—and technological parameters, drawing conclusions regarding the machinability of various materials.

Geometrical Characteristics of Kerf width on Titanium Alloy by Abrasive Water Jet Machining

Geometrical Characteristics of Kerf width on Titanium Alloy by Abrasive Water Jet Machining

Research on high‐pressure abrasive water jet slotting and pressure relief technology for hard rock roof

AbstractTo solve the problem of severe rock pressure near coal mining face tunnels, a high‐pressure abrasive water jet slotting and roof breaking pressure relief technology is proposed. First, the laneway deformation mechanism and the process of hard rock slotting using high‐pressure abrasive water jets under long‐distance cantilever conditions are analyzed, and the crack initiation conditions of roof strata are obtained. Second, slotting tests under different slotting pressures, nozzle diameters, abrasive particle sizes and slotting times were carried out, and the slotting parameters of a high‐pressure abrasive water jet on a typical roof rock were obtained. Finally, industrial application was carried out in the 81,403 working face of Huayang No.1 Mine. After the hydraulic roof slotting measures were implemented in the test area, the maximum axial force of the anchor cable was reduced to 67 kN, which was 35.5% lower than that of the comparison. The average stress of the coal seam was 15 MPa, which was approximately 25% lower than that of the comparison. The deformation of the tunnel in the experimental area was significantly controlled, with an average movement of 30.0% toward the roof and floor of the tunnel and an average movement of 23.2% toward the two sides of the tunnel. Compared with the movement in the comparison section, the movement toward the roof and floor of the laneway was 42.3% lower, and the movement toward the two sides was 38.2% lower. The industrial application results show that high‐pressure abrasive water jet roof slotting and pressure relief technology can cut off the stress transmission path between the roof rock on both sides, effectively improve the stress state of the surrounding rock of the laneway, reduce the deformation of the roof, floor and two sides of the working face in the later stage of the mining laneway.

Experimental study on optimization of abrasive water jet process parameters

Abstract In order to improve the mining speed of coal mine roadway and fundamentally solve the problem of mining imbalance, the abrasive water jet technology is used to cut rocks in front of mechanical tools to achieve efficient improvement of coal mine roadway mining efficiency. Based on the existing high pressure pure water jet test equipment, the abrasive water jet test platform was built, and the uniaxial compressive strength of soft and hard rock was obtained by testing the rock mechanical properties. The effect of jet pressure, target distance, transverse velocity and jet impact Angle on rock cutting is studied by using control variable method. According to the single factor test analysis, L16 (44) four-factor four-level orthogonal test analysis table is selected to carry out orthogonal tests on granite and sandstone respectively. The results of range analysis and variance analysis show that the main and secondary relationships of abrasive water jet factors are as follows: transverse velocity > jet pressure > jet inclination > target distance. The optimal jet parameters are when jet pressure is 40 MPa, target distance is 5mm, transverse velocity is 2mm/s and jet inclination is 10°.

The Abrasive Water Jet Cutting Process of Carbon-Fiber-Reinforced Polylactic Acid Samples Obtained by Additive Manufacturing: A Comparative Analysis

Carbon-fiber-reinforced polymer (CFRP) composites are widely used across industries due to their enhanced strength and stiffness properties. Fused deposition modeling (FDM) enables the cost-effective production of polymer samples, such as carbon-fiber-reinforced PLA (CFR-PLA). However, CFRP’s hardness and anisotropic nature present significant challenges in conventional machining, including rapid tool wear and thermal sensitivity. Consequently, abrasive water jet machining (AWJM) has proven to be an effective alternative for machining CFRP materials, offering benefits such as reduced tool wear, minimized thermal damage, and improved cutting quality. This study focuses on a comparative analysis of the effects of AWJM parameters on PLA and CFR-PLA samples, specifically to evaluate the influence of carbon fiber reinforcement on machining performance. The findings highlight the critical role of reinforcements in machining behavior. The results suggest that optimizing cutting parameters significantly reduces taper formation and improves machining accuracy. In particular, adjustments to process parameters resulted in lower taper angles and reduced surface roughness in the cutting zones of the CFR-PLA samples.

Influence of brown algae filler and process parameters on the surface roughness and MRR of jute fiber polymeric composite machined by abrasive water jet

Traditional manufacturing of polymeric composite leads to delamination. Implementing abrasive water jet machining (AWJM) presents a sustainable solution for shaping the polymeric composites, thereby eliminating the need to dispose of chemically contaminated waste. Brown microalgae, commonly found in aquatic environments, serve as viable additives for enhancing the properties of polymeric composites. This study entails the polymeric composite reinforced with jute fiber fabricated by modulating the weight percentages of brown algae powder by 0, 3, and 6 wt.% utilizing the hand layup procedure. The composites were formed and subsequently subjected to drilling by AWJ machining filled with brown algae. The experimental investigation was done to analyze the effect of AWJ parameters: water jet pressure (WJP), traverse speed (TS), and stand-off distance (SoD)—on the material removal rate (MRR) and average surface roughness ( Ra). Orthogonal Array L27 experimental results revealed that polymeric composite reinforced with jute fiber containing 3 wt.% of brown algae exhibited the highest MRR, with an increase of up to 12% compared to other samples. Additionally, these composites demonstrated a significant reduction in surface roughness, reaching up to 8% when compared to alternative samples. Utilizing the Taguchi-based ANOVA method facilitated a systematic exploration and identification of influential factors impacting both MRR and Ra in AWJ machining. Notably, the WJP and SoD emerged as key factors significantly influencing both MRR and Ra.

Analysis and optimization of abrasive waterjet dressing parameters for surface texturing of diamond grinding wheels

With the development of ultra-precision machining technology, the grinding performance of diamond grinding wheels has put forward higher requirements. In this study, a new method of dressing diamond grinding wheels using abrasive waterjet (AWJ) technology is proposed to address the issues of workpiece damage and wheel clogging that occur when grinding difficult-to-machine materials with conventional diamond grinding wheels. The main process parameters were determined based on the theoretical model for dressing diamond grinding wheels using AWJ. The response surface methodology (RSM) and the backpropagation artificial neural network (BP-ANN) were employed to establish regression models between process parameters and microgroove characteristics. A comparison was performed to evaluate the prediction performance of both RSM and BP-ANN. The results indicated that both approaches BP-ANN and RSM are powerful tools for predicting microgroove characteristics. This work provides theoretical guidance for texturing diamond wheels surface.