Cavitation Erosion Resistance Research Articles

A Novel Approach for Rapid Evaluating Cavitation Erosion Resistance of Metallic Materials

A Novel Approach for Rapid Evaluating Cavitation Erosion Resistance of Metallic Materials

Effect of Co Contents on Microstructure and Cavitation Erosion Resistance of NiTiAlCrCoxN Films

Effect of Co Contents on Microstructure and Cavitation Erosion Resistance of NiTiAlCrCoxN Films

Interfacial Alloying between Expanded Austenite and Ti(AlCu)N Coating for Enhanced Cavitation Erosion Resistance

Duplex surface treatments, combining nitriding and PVD coatings, have been considered as potential solutions to enhance material cavitation erosion resistance. This study investigates 316L stainless steels after active screen plasma nitriding (ASPN), Ti(AlCu)N coating and duplex-treatment (Duplex) for enhanced cavitation erosion resistance. We elucidate a ‘denitriding - nitriding’ alloying behavior in association with high-energy ion sputtering for the interface between the nitrided case and the Ti(AlCu)N coating in the duplex-treated 316L surface. Comparing the cavitation erosion performance among ASPN, Ti(AlCu)N and Duplex, the lowest weight loss of the duplex-treated surface is attributable to the enhanced load-bearing capacity from the multilayer system and the strong coating adhesion (HF1) after metallurgical evolution at the interfacial zone.

Effects of heat treatment on the nano-indentation, corrosion and cavitation erosion behavior of 17-4PH stainless steel by laser surface melting

The effects of heat treatment on the microstructure, residual stresses, nano-indentation behavior, the resistance to the corrosion and cavitation erosion (CE) of 17-4PH stainless steel (17-4PH SS) by laser surface melting (LSM) were thoroughly investigated. Experimental results showed that the samples were mainly composed of martensite phase, and the NbC precipitations formed after heat treatment. The distribution of NbC precipitations was more uniform in the sample (S3) after solution treatment 3 h at 1040 °C + aging treatment 3 h at 480 °C. The grain size was increased for the samples after heat treatment. This heat treatment processing significantly reduced the residual stresses generated from the LSM process, and the nano-indentation behavior of the LSM samples after heat treatment was improved compared to that of the LSM sample without heat treatment. The S3 sample displayed the highest corrosion resistance as indicated by the low corrosion current density (icorr), high pitting potential (Epit) and high polarization resistance (Rp). The CE resistance of samples after heat treatment in 3.5 wt% NaCl solution was higher than that of the sample without heat treatment. Among them, the S3 sample exhibited the highest CE resistance, and its CE mass loss was only 59.5 % of the sample without heat treatment. The excellent CE resistance resulted from the appropriate combination of mechanical properties, corrosion resistance and self-recovery ability of the passivation film.

Comparison of the corrosion and cavitation erosion behaviors of the cast and surface-modified manganese-aluminum bronzes in sodium chloride solution

Modified layers with refined and homogenized microstructure were obtained on a cast manganese aluminum bronze (MAB) by friction stir processing (FSP) and laser surface melting (LSM). In 3.5% NaCl solution, a much more protective film was formed and uniform corrosion occurred for the two surface-modified MABs. The corrosion rate of the cast sample was reduced by a factor of 29.73% after FSP and 51.35% after LSM. The cavitation erosion (CE) rate of the cast MAB was about 1.83 and 3.07 times larger than that of the FSP and LSM samples, respectively. The CE resistance increment was highly attributed to the improved hardness and enhanced nano-indentation behavior after FSP or LSM. For each MAB, the CE resistance decreased with extended pre-immersion time. Compared with the result of the correspondingly freshly-prepared sample, the CE rate was raised by a factor of 36.22%, 42.97% and 44.00% after 30 days’ pre-immersion for the cast, FSP and LSM MABs, respectively. For the cast and FSP MABs, mechanical impact was the leading factor accounting for CE degradation. For the pre-corroded samples, corrosion damage at the β and κ phases weakened the mechanical properties and thus triggered more grievous material exfoliation under CE. For the LSM MAB, CE-corrosion synergy dominantly gave rise to the CE damage. Corrosion at grain boundaries after pre-immersion also deteriorated the CE performance. The LSM MAB possessed the highest corrosion and CE resistances because the fine single-phase microstructure reduced the galvanic corrosion effect and crack propagation tendency under CE impact.

Effects of plastic deformation ability and fluid medium on the cavitation erosion behavior of carbon nanotube reinforced cermet coatings

In this work, the cermet/MWCNTs powder was manufactured and the composite coatings with MWCNTs-reinforced interlayer interface were fabricated by the high-velocity oxygen-fuel (HVOF) spraying to enhance the cavitation erosion resistance (CER). MWCNTs effectively reduced the porosities and increased the plastic deformation ability of the composite coatings. In distilled water, MWCNTs in the interlayer dispersed stress and inhibited crack initiation during cavitation erosion. The incorporation of 0.2 wt% MWCNTs led to a significant enhancement in the CER of the composite coatings, exhibiting an improvement rate of 39.34%. The cavitation erosion mechanism changed from micro-jet impact to micro-particle impact in SiO2 dispersion. The spalling effect during the micro-particle impact process diminished the reinforcement of MWCNTs and the CER of the composite coatings.

Enhancing cavitation erosion resistance of VC+TiC coatings with PTFE in marine environments via lasso regression optimization

This research explores the mechanical properties and erosion mechanisms of SS316, VC+TiC, and PTFE coatings to study cavitation erosion resistance. Microhardness analysis revealed that VC+TiC showed the highest resilience due to its hardness, while PTFE, despite lower hardness, displayed potential with formulation adjustments. Lasso Regression models effectively predicted mass loss under various testing conditions, indicating strong relationships between independent variables and erosion responses. Scanning Electron Microscopy (SEM) analysis uncovered distinct erosion mechanisms for each coating, with SS316 showing plastic deformation, VC+TiC exhibiting crater formation, and PTFE displaying torn splats. The development of superhydrophobic surfaces from VC+TiC and PTFE coatings offers promising applications in mitigating cavitation erosion, providing valuable material-specific insights into this phenomenon.

An investigation on the effect of heat input to wear behavior and corrosion-cavitation erosion mechanism of Hastelloy C-276 coating by cold metal transfer

Cold metal transfer (CMT) technology based on wire-arc manufacturing has attracted wide attention because of its advantages of high manufacturing efficiency, low heat input (HI) and near-net-shape. In this study, a CMT-Hastelloy C-276 superalloy surface modification coating by optimizing HI is used to solve the problem of premature failure of key over-flow components of stainless steel in marine engineering. When the HI is increased from 269 J/mm to 358 J/mm, the serious cavitation erosion (CE) damage caused by pore defects and excessive residual tensile stress due to excessive low HI of Hastelloy C-276 coating can be avoid, which is attributed to the effective Orowan strengthening and high proportion of low angle grain bounds (LAGBs: 70.2%). In addition, high contents of Cr, Mo and W elements can promote it's passivation film to maintain excellent self-healing ability during CE to provide continuous and stable protection effect (Rct = 75.68 kΩ·cm2) in the 3.5 wt% NaCl artificial seawater. Therefore, even after 10 h-CE, it still maintains the highest corrosion resistance from both of the thermodynamic (Ecorr = −193.5 ± 3.6 mV) and kinetic perspective (Icorr = 69.3 ± 3.1 μA·cm−2) and has the lowest mean depth erosion rates (MDER, 0.94 ± 0.07 μm/h). However, further increase of HI will cause coarsing of grains (89.6 ± 2.7 μm → 342.8 ± 9.7 μm), excessive precipitation of brittle Mo-rich p phase and excessive dilution of elements from the substrate, resulting in changes in the wear mechanism and deterioration of strength and corrosion resistance. Moreover, the potential of zero charge (PZC) measurements and Mott-Schottky (M-S) test confirmed the decreasing trend of the repulsive ability to Cl ions (ΔE = 0.58 V) and the increased ion doping concentration (ND = 5.94 ± 0.02 × 1022 cm−3) of the weakened n-type passivation films. The optimal combination of wear resistance, corrosion resistance and CE resistance of Hastelloy C-276 coating is obtained by regulating HI, which can lay a theoretical foundation for the related production and application of marine engineering.

Preparation and cavitation erosion resistance of nanocrystalline surface layer on 304 stainless steels

Cavitation erosion is a common damage form of hydraulic components. Constructing a cavitation-erosion-resistant layer on the surface of hydrodynamic components can effectively prolong the service life of the equipment. In this study, 304 austenitic stainless steel was machined by a diamond blade under specific processing parameters, and a nanocrystalline layer (304-Nano) was formed by the work hardening during the machining process. The machining process also allowed strain-induced martensitic transformation, creating martensite in the nanocrystalline layer. The nanocrystalline layer had an average grain size of approximately 34.7 nm, showing a Vickers hardness of 600 ± 30 Hv, which was much higher than that of the original 304 austenitic stainless steel (230 ± 14 Hv). After the 15-h cavitation erosion test, the cavitation erosion rate of the 304-Nano sample was only 19.4 % that of the original ordinary 304 stainless steel, showing that the 304-Nano sample has excellent cavitation erosion resistance. Furthermore, the in-situ SEM results showed that the 304-Nano sample could significantly inhibit crack propagation, which was probably attributed to its high density of grain boundaries and ultrahigh hardness. The excellent cavitation erosion resistance of the nanocrystalline layer is expected to be used as a protective material for anti-cavitation erosion applications.

A Review of Cavitation Erosion on Pumps and Valves in Nuclear Power Plants.

The cavitation erosion failure of pumps or valves induces the low efficiency and reduced service life of nuclear reactors. This paper reviews works regarding the cavitation erosion of pumps and valves in the nuclear power industry and academic research field. The cavitation erosion mechanisms of materials of pumps and valves are related to the microstructure and mechanical properties of the surface layer. The cavitation erosion resistance of austenitic stainless steel can be ten times higher than that of ferritic steel. The cavitation erosion of materials is related to the hardness, toughness, and martensitic transformation capacity. Erosion wear and erosion-corrosion research is also reviewed. Erosion wear is mainly influenced by the hardness of the material surface. Erosion-corrosion behavior is closely connected with the element composition. Measures for improving the cavitation erosion of pumps and valves are summarized in this paper. The cavitation erosion resistance of metallic materials can be enhanced by adding elements and coatings. Adhesion, inclusion content, and residual stress impact the cavitation erosion of materials with coatings.

Improved corrosion and cavitation erosion resistance of laser-based powder bed fusion produced Ti-6Al-4V alloy by pulsed magnetic field treatment

The application of pulsed magnetic field (PMF) treatment demonstrated enhanced corrosion resistance in saline solution and prolonged resistance to cavitation erosion in deionised water for Ti-6AI-4V alloy manufactured by laser-based powder bed fusion (LPBF) and conventional wrought processing methods. The observed outcomes were attributed to the formation of a denser protective surface oxide layer and microstructural changes, resulting in a reduction of the α' phase by 0.13% and an increase in the presence of dislocations at the surface. Consequently, this led to an increase in the compressive residual stresses. Additionally, the application of this treatment resulted in the formation of highly refined and uniform precipitates, leading to a notable enhancement in microhardness by 5.73% and 5.85% for the conventionally manufactured (CM) and LPBF samples, respectively.

Methods for increasing the cavitation and solid particle erosion resistance of 20GL and 30L steels based on their surface modification

The article presents the results of studies of cavitation and solid particle erosion resistance of samples of 20GL and 30L steels with various surface modification options based on nitriding and boriding processes. Tests for cavitation resistance were carried out according to the ASTM G134-17, and for solid particle erosion resistance - according to the ASTM G76-13. It was revealed that to increase wear resistance, the depth of modification of the considered steels should be at least 80 microns. Based on the totality of cavitation and solid particle erosion studies carried out, the best option for surface modification for 20GL steel is boriding, and for 30L steel nitriding.

A study of cavitation erosion resistance of an ion nitrided titanium alloy by means of the vibration and rotating disk methods

In this work, a comparative analysis of the cavitation erosion resistance of the Ti–6.7Al–2.5Mo–1.8Cr–0.5Fe–0.25Si alloy (known as brand VT3-1) before and after low-temperature ion nitriding is carried out. Two test methods were applied, using vibrative (ASTM G-32) and rotating disk rigs, respectively. The kinetic dependences of the erosive destruction of samples of titanium alloy VT3-1 in the initial state, after ion nitriding and stainless steel AISI 321 were obtained. A study of the microstructure, hardness and surface morphology was carried out. The samples were examined using optical and scanning electron microscopy. The relationship between mass loss and cavitation erosion duration was experimentally determined and analyzed. The erosion rate on a rotating disk stand is much higher than during vibration tests. A large cavitation load gradient provides additional opportunities for analyzing the durability of materials and coatings using this method.

Effect of Y2O3 doping content on phase composition, mechanical properties and cavitation erosion performance of ZrO2 ceramics

Y2O3 stabilized ZrO2 (YSZ) is considered to be promising in resisting force-heat coupling damage caused by cavitation erosion (CE). However, the impact of doping Y2O3 on the microstructure and properties of ZrO2 is extremely complex, and there is still a lack of understanding about it, let alone the mechanism of these factors on the CE performance. In light of this, the present study investigated the effects of Y2O3 doping content (3 mol%, 7 mol% and 17 mol%) on the phase composition, grain size, microstructure, density, mechanical properties and CE performance of YSZ, and deeply analyzed the CE mechanism. The results indicated that the Y3+ entering the zirconia lattice effectively stabilized the high-temperature phases (t, t′ and c) and suppressed the formation of m-phase. With the increase of Y3+ concentration, the content of t continuously decreased while that of c continuously increased, so that only t + t′ phases were contained in the 3YSZ and only t′+c phases were contained in the 17YSZ. Meanwhile, the grain sizes and pores were constantly increasing, which obviously deteriorated the hardness, toughness and CE resistance. The t→m transformation under the action of cavitation load effectively absorbed impact energy and suppressed the propagation of fatigue cracks, thereby significantly delaying the fatigue spallation of materials. The 3YSZ with the densest microstructure, the best mechanical properties, the smallest grain size and the highest content of t-phase exhibited the best CE resistance. However, the continuous accumulation of m-phase at the grain edge, especially the amorphous structure formed by hydrolysis promoted by cavitation heat, provided a preferential channel for the propagation of fatigue cracks, and thus ultimately led to the exfoliation of the grains.

Iso-material manufacturing of 304 stainless steel: Microstructure, corrosion-cavitation erosion synergistic behaviour

Different from additive or subtractive manufacturing, iso-material manufacturing (also named isovolumetric manufacturing) was proposed in this work by laser surface melting (LSM), aiming at enhancing resistance to corrosion and cavitation erosion (CE) of 304 stainless steel. Experimental results showed that partial austenite transformed into martensite after LSM. The corrosion resistance of LSMed sample was improved. LSMed sample exhibited enhanced CE resistance, and was 2.5 and 2 times that of untreated sample in deionised water and 3.5 wt% NaCl solution, respectively. The passivation film for LSMed sample exhibited a high re-passive and self-repairing ability of passivation film. LSMed sample in this study exhibits a high or comparable corrosion and CE resistance in comparison with samples prepared by other fabrication method reported previously.

Developing thermal insulation cement-based mortars with recycled aggregate in accordance with net zero principles

The performance of thermo-insulation rendering mortars with alternations in ratios of powdered cordierite and talc was examined. The goal was to confirm that recycled kilnware cordierite can be reapplied in the mortar design without significant deterioration in performance in comparison with OPC mortar. Differential thermal analysis was employed for examining thermally induced reactions. The cavitation erosion, in testing sequences ranging from 30 to 120 minutes, was used to assess the compactness of the mortar structure. The physico-mechanical properties of experimental mortars were investigated. The morphologies of the mortar tablets upon cavitation were studied using a scanning electron microscope. It was established that cordierite and talc filler in amounts up to 20% enhance microstructural packing and mechanical strengths due to improved cementation and therefore contribute to cavitation erosion resistance. Higher amounts of talc cause structural degradation and mass loss during cavitation tests. Reducing manufacturing costs, energy consumption, and greenhouse gas emissions are the main objectives of the production of this waste-based construction composite, as the reuse of waste materials can help achieve a number of Sustainable Development Goals.

Cavitation erosion resistance of 1.2709 alloy produced via Laser-Powder Bed Fusion

Maraging steels, like 1.2709 (18Ni-300), are attractive materials for the aerospace, automotive, tooling, and bearing gear industries because of their high yield, tensile strength, and good toughness. The low-carbon martensite matrix and nanoscale intermetallic precipitates combine to provide distinctive mechanical properties. In particular, due to their low carbon content, these steels are easily weldable and are therefore appropriate for additive manufacturing (AM) processes like laser-based powder bed fusion (LPBF). The tooling and molding industry has just lately started using this fabrication technique to create inserts with conformal cooling channels that can extend the lifetime of the insert and core while boosting the cast quality. These parts are frequently exposed to high levels of stress, wear, and even aggressive conditions. In this context, this research focuses on a peculiar, and thus understudied, erosion phenomenon known as cavitation erosion. According to the ASTM G32 standard, the cavitation erosion resistance of 1.2709 maraging steel samples produced by additive manufacturing as well as by forging was investigated. Microstructural analyses were carried out to evaluate the effect of the different microstructures resulting from the different manufacturing techniques on erosion behavior. When compared to the forged maraging steel, the AM one shows less resistance to the initiation of the erosion phenomenon. Nevertheless, the wear rates of the two materials are comparable.

Insight into continuous growth mechanisms of ZrO2-Al2O3 composite PEO coatings with superior cavitation erosion resistance

The ZrO2-Al2O3 composite coatings were fabricated on TiB2/2024Al composite by the plasma electrolytic oxidation (PEO) treatment with either monoclinic (m-ZrO2) or tetragonal zirconia (t-ZrO2) nanoparticles (NPs) addition. Such PEO coatings showed a double layer morphology due to the limited physical motion ability of ZrO2 colloidal particles into coatings. t-ZrO2 remained as the main phase in ZrO2-Al2O3 PEO composite coatings whether t-ZrO2 or m-ZrO2 NPs were added. Based on the microstructure analyses by focus ion beam plus scanning electron microscopy and transmission electron microscopy, ZrO2 showed netlike morphology in the outer layer with NPs partially melted at the mesh boundary and lines-like morphology fully melted at the inner mesh in the coating. A prominent morphological transition of ZrO2 was clearly observed at the interface between outer layer and inner layer. Therefore, the continuous growth mechanisms of ZrO2-Al2O3 composite PEO coatings were proposed in terms of morphological evolution process. Furthermore, electrochemical measurements and cavitation erosion tests were conducted to study the comprehensive surface properties (corrosion and impact resistance) of ZrO2-Al2O3 composite coatings. As a result, the ZrO2-Al2O3 composite PEO coatings with m-ZrO2 addition exhibited the greatly reduced corrosion rate, and superior cavitation erosion resistance. Accordingly, the underlying mechanisms for these improved properties were intensively discussed.

Microstructure development and cavitation erosion resistance enhancement of additive manufactured Hastelloy C276 alloy coating on martensitic stainless–steel via directed energy deposition

In this study, a Hastelloy C276 coating was prepared on a martensitic stainless-steel substrate using laser melting deposition, aiming at obtaining a coating with high resistance to cavitation erosion. The coating is up to 600 μm thick, and the grain morphology of the coating exhibits a progression from bottom to top, transitioning from cellular to columnar and ultimately to equiaxed grains. Additionally, the grains grow at a specific angle to the substrate plane, following the direction of the heat source. A 200 μm thick compositional mixing zone is formed at the interface of the substrate and the coating, in which the coating elements and substrate elements mutually permeate and form a stable metallurgical bond. The microhardness of the coating is measured as 334.4 HV0.05, signifying a substantial improvement of 33.2 % compared to the substrate. The cavitation erosion process of the coating can be classified into three stages: incubation, accumulation, and stabilization. The material spalling damage caused by cavitation erosion progresses in a fatigued manner, and the coating demonstrates considerably enhanced resistance to cavitation erosion compared to the substrate.

Effect of 3.5 % NaCl solution with different Na2S concentrations on ultrasonic cavitation erosion behaviors of HVOF sprayed WC-Ni coatings

In this article, the WC-10Ni coatings were fabricated by HVOF spray, then the ultrasonic cavitation erosion performances of the coatings in distilled water and 3.5 wt% NaCl solution with various Na2S concentrations (0, 20 and 200 ppm) were investigated. The results of the cumulative volume loss of the coating in different mediums showed that the coating exhibited enhanced cavitation erosion resistance with the increase of Na2S concentrations in medium. The reason for the improvement on the cavitation erosion performance was the growth of corrosion product films containing sulphide. In comparison with the coating after cavitation erosion in medium without Na2S, no large craters and deep grooves were observed on the eroded coating surface in medium with Na2S. The ultrasonic cavitation damage of the coating manifests as the spall of the metal binder phase (Ni) and exposure of the hard phase (WC).