Erodent Size Research Articles

Erosion wear behavior of needle-punched nonwoven fabric (NPNF) reinforced epoxy composites – An evaluation using Taguchi’s design

This article depicts the solid particle erosion response of polymer matrix composite (PMCs) reinforced with a textile material i.e., needle-punched nonwoven fabric (NPNF) under the impingement of such solid particle at different velocities and angles. The influence of six experimental parameters (i.e. impact velocity, fiber loading, angle of impingement, area density, erodent size, and stand-off-distance) with three different levels each on performance output (i.e., wear rate) are studied from erosion trails using Taguchi’s L27 orthogonal array design. Based on analysis of signal-to-noise ratio obtained from this Taguchi’s design of experiment approach, predominantly influential parameters affecting the erosion wear rate are identified.

Effect of erosion on corrosion of API X120 steel in relation to erodent particle size

The nature of the solid erodent particles present in corrosive petroleum fluid can cause transporting pipeline to experience severe erosion and corrosion damages. The effect of erosion on corrosion behavior of API X120 steel was investigated using aluminum oxide and silicon carbide particles with different sizes as erodent and 3.5 wt.% NaCl aqueous solution saturated with carbon dioxide as a corrosive medium. The effect of the erodent particle size on the corrosion behavior of the steel material at different particle speeds and impact angles was investigated using weight loss, potentiodynamic polarization and surface analysis techniques. The erosion results confirmed that the material damage increased with increasing particle speed. It was observed that in carbon dioxide-saturated saline solution, deposition of protective iron carbonate film occurred on the steel surface. It was found that the corrosion film can provide better protection at lower particle speed than at higher speed. The ratio of total erosion–corrosion (S)/effect of erosion on corrosion (T) analysis confirmed that at higher S/T ratio, the particle speed and material removal rate are low and vice versa at lower S/T ratio. Lower S/T values for the combined erosion and corrosion tests performed with erodent silicon carbide particle compared to erodent aluminum oxide particle showed that erosion enhancement of corrosion is more evident in the test performed using aluminum oxide particle than using silicon carbide particle. The result also suggests that when subjected to larger size erodent particle, the damage to pipeline due to effect of erosion on corrosion process can be more significant compared to smaller size erodent particle.

Influence of dolomite on mechanical, physical and erosive wear properties of natural-synthetic fiber reinforced epoxy composites

The study was intended to investigate the influence of dolomite content on the physical, mechanical and erosive wear properties of hybrid natural—synthetic fiber reinforced polymer composites. Therefore, epoxy composites, having fixed amount of Grewia optiva and glass fiber with varying proportion of dolomite particles (0, 5, 10 and 15 wt%) were developed with hand-layout technique. The results show that the density, void content, impact energy and hardness increases, while flexural and tensile strength decreases with the increase of dolomite content. For erosive wear analysis, Taguchi method with L16 orthogonal array was used. The experiments were performed on an air jet machine with different impingement angles (30, 45, 60 and 90°), erodent sizes (100, 150, 200 and 250 μm) and impact velocities (10, 20, 30 and 40 m s−1). The lowest wear rate was achieved under optimal condition of 10 wt% dolomite content, 30° impingement angle, 10 m s−1 impact velocity and 150 μm erodent size. Moreover, scanning electron microscopy was implemented in order to analyze the eroded composite surfaces for possible wear mechanism.

Impact of high‐velocity oxy‐fuel sprayed TiAlN surface coating on mechanical and slurry erosion performance of aluminium alloys

AbstractTiAlN coatings were deposited on AA1050 and AA5083 aluminium alloys by high‐velocity oxy‐fuel (HVOF) spray process and evaluated for their mechanical and slurry erosion performance. In comparison to base alloys, the mechanical properties were found to enhance upon coating. The effect of working parameters namely impingement angle, impact velocity, erodent size and erodent feed rate on the slurry erosion wear rate has been investigated. The slurry erosion wear rate of the uncoated samples was found to decrease with an increase in the impingement angle whereas for coated samples the slurry erosion wear rate first increased, reached to a maximum value at 60° and then decreased with further increase in the impingement angle. For uncoated and coated samples the slurry erosion wear rate was found to increase with an increase in impact velocity, erodent size and erodent feed rate. Finally, the morphology of the eroded surfaces was analyzed using scanning electron microscopy and the possible erosion mechanisms have been studied.

Erosive wear characteristics of E‐glass fiber reinforced silica fume and zinc oxide‐filled epoxy resin composites

AbstractIn the present study, the effect of addition of silica fume, also known as microsilica, and zinc oxide fillers on the erosive wear behavior of bidirectional E‐glass fiber‐based epoxy resin composites has been investigated. The amount of silica fume and zinc oxide fillers in the composites was changed in the interval from 0 to 16 wt.%. The erosive wear of the composites has been evaluated at different impingement angles from 20° to 90° and at four different impact velocities of 70, 100, 150, and 200 m/s. The erodent particles used were silicon carbide (SiC) with the average particle sizes of 72 μm, 175 μm, and 348 μm, respectively. The results show that the erosion rate increases with increasing impingement angle, impact velocity, exposure time, and erodent particle size in all the composites. By comparing the two types of fillers, the composites filled with silica fume showed better erosion resistance than those of zinc oxide‐filled composites at the same filler loading. The composite filled with 16 wt.% silica fume presented the best erosion resistant while the highest erosion rate was obtained at the composite filled with 16 wt.% zinc oxide. The morphology of eroded surfaces was examined by using scanning electron microscopy, and possible erosion mechanisms were discussed.

Characterization and Accelerated Erosion Testing of WC-Co-Cr- and CoNiCrAlY-Coated CA6NM Turbine Steel

In the present study, in-depth characterization of the high-velocity oxy-fuel (HVOF)-spray WC-Co-Cr and CoNiCrAlY coatings deposited on CA6NM turbine steel was done using scanning electron microscope (SEM), x-ray diffraction (XRD), roughness tester, microhardness tester, and optical image analyzer. Further, these coatings were tested under accelerated slurry erosion conditions using a high-speed erosion test rig. The effects of three different parameters related to actual operating conditions, namely erodent velocity relative to target surface, average erodent particle size, and slurry concentration on erosion behavior of these coatings, were investigated. SEM images on the specimen surface taken before and after erosion tests were carefully examined to understand the possible erosion mechanism. The study revealed that HVOF-sprayed WC-Co-Cr coating was found to impart higher erosion resistance in comparison with CoNiCrAlY coating under all the slurry erosion conditions. The reason for this behavior may be attributed to the higher hardness of HVOF-sprayed WC-10Co-4Cr coating in comparison with CoNiCrAlY coating.

Erosion Wear Behavior of SiC Nano Powder Filled Flax and Sisal Fabric Hybrid Composites with Taguchi Experimental Design

This work is carried out to find out the erosion wear characteristics of unfilled and also SiC nanopowder filled flax and sisal fabric hybrid composites (FSHC). Effect of different parameters such as filler content, impingement angle and erodent size on the erosion wear behavior of hybrid composite has been studied using Taguchi method. Significant control factors altering the erosion rate have been evaluated through outstanding execution ANOVA. The experimental outcomes are recognized to be in acceptable accord with the assumptive values. This study indicates that erosion wear resistance increases as SiC nanopowder increases in FSHC

Analysis of Artificial Neural Network for Predicting Erosive Wear of Nylon-12 Polymer

Abstract In this study, artificial neural network (ANN) is applied to predict the erosion rate of nylon-12 polymer to ensure the accuracy of soft computing. The ANN model was developed with 4 neurons in the input layer, 10 neurons in the hidden layer, and 1 neuron in the output layer. A backpropagation algorithm was utilized in a multilayered perception. The inputs include impact velocity (m/s), impingement angle (°), erodent size (μm), and stand-off distance (mm). Experimental data were used to predict the erosion rate in relation to the input parameters. The size of the erosive element of randomly shaped sand particles (silicon dioxide) is set between 300 and 600 μm, the impact velocity between 30 and 50 m/s, the impingement angle between 30° and 90°, and the stand-off distance between 15 and 25 mm. The consistency between the experimental and ANN model values, with an accuracy of 94.428 % and root mean square error of 9.729, signifies that the proposed ANN model is suitable for predicting the erosion rate of nylon-12 polymer. The prediction made using the ANN model was in good agreement with the experimental results. The ANN model can be used to estimate the maximum and total erosion rate of nylon-12 with high reliability. Therefore, this model can be applied for practical purposes.

Fabrication of waste bagasse fiber‐reinforced epoxy composites: Study of physical, mechanical, and erosion properties

The aim of the research work is to study the physical, mechanical, and erosive wear properties of sugarcane bagasse fiber‐reinforced epoxy composites. The physical (density, void content) and the mechanical (hardness, tensile strength, impact energy, flexural strength) properties of the composites were found to increase with the content of bagasse fiber. For erosive wear analysis, the experiments were carried out with the help of erosion test machine. To minimize the erosive wear rate, Taguchi technique is executed to explore the influence of five control factors including fiber content, impact velocity, impingement, stand‐off distance, and erodent size at three levels. Using Taguchi (L27) orthogonal array, the optimal combination of control factors, which yielded minimum erosive wear rate, was statistically predicted and experimentally verified. The fiber content and impact velocity were the two most contributing control factors for the minimization of erosive wear rate. The important sequence of the parameters is fiber content > impact velocity > impingement angle > erodent size > stand‐off distance. The optimal combination of control factors was obtained at 10 wt% of fiber content, 30 m/s of impact velocity, 30° of impingement angle, 85 mm of stand‐off distance, and 250 μm of erodent size. Finally, composites worn surfaces were examined with scanning electron microscope to study the possible erosive wear mechanism. POLYM. COMPOS., 40:3777–3786, 2019. © 2019 Society of Plastics Engineers

Prediction and Optimization of Erosion Rate of Carbon Fiber–Reinforced Ebonite Using Fuzzy Logic

Abstract In this study, a fuzzy artificial intelligence approach is utilized to predict the erosion rate of reinforced ebonite composite materials with carbon fiber owing to the significant accuracy of soft computing techniques. Experimental data were used to predict the erosion rate with respect to the input testing conditions, namely, impact velocity, impingement angle, erodent size, and stand-off distance. The size of the erosive element of randomly shaped sand particles (silicon dioxide) is set between 300 and 600 μm. Other input process parameters, such as the impact velocity between 30 and 50 m/s, the impingement angle between 30° and 90°, and the stand-off distance between 15 and 25 mm, are selected. The consistency between the experimental and fuzzy logic model values, with a 94.45 % accuracy, signifies that the proposed fuzzy logic model is suitable for predicting the erosion rate of reinforced ebonite composite materials. The maximum erosion rate is obtained between a 50° and 60° impingement angle. Morphological images are analyzed by scanning electron microscopy to elucidate the erosion mechanisms.

Parametric Optimization of Erosive Wear Response of TiAlN-Coated Aluminium Alloy Using Taguchi Method

In this research work, high-velocity oxy-fuel thermal spraying is used to develop TiAlN coatings on AA1050 and AA5083 aluminium alloy substrates. Slurry wear behavior of coatings is evaluated using jet-type test rig. Surface studies were carried out to investigate the potential erosion mechanism. The influence of key parameters identified using the Taguchi analysis is also corroborated with a wear model. The potential mechanism identified by wear model is in excellent convergence with that observed experimentally. Mixed ploughing and cutting, formation of platelets, abrasion grooves and cracks are witnessed as primary mechanisms causing loss of coating. Results indicate that impact velocity is recognized as a highly contributing parameter with contribution ratio of 79.24 and 83.75% followed by impingement angle with contribution ratio of 15.81 and 11.58% for AA1050 and AA5083, respectively. The important sequences of the control parameters are recognized to be impact velocity > impingement angle > erodent feed rate > erodent size for AA1050 and impact velocity > impingement angle > erodent size > erodent feed rate for AA5083. The best possible combination of control parameters for AA1050 and AA5083 to achieve minimal wear rate with respect to impact velocity, erodent size, impingement angle and erodent feed rate is 30 m/s, 225 µm, 30°, 160 g/min and 25 m/s, 150 µm, 30°, 160 g/min, respectively.

Slurry jet erosion performance of high-velocity flame-sprayed nano mixed Ni-40Al2O3 coating in aggressive environment

Hydro turbine components are subjected to severe erosion especially during the rainy season in the Himalayan region. To protect the CA6NM turbine steel, an attempt has been made to develop the Ni-40Al2O3 composite coating using a high-velocity flame spray process. To lower the porosity, the coating was developed by mixing two different sizes (viz. micron and nano) of alumina (Al2O3) reinforcement with 60 wt.% Ni as the base powder. The characterization of the as-sprayed coating was done by scanning electron microscopy/energy dispersive X-ray spectroscopy, and PANalytical X-ray diffraction technique, whereas mechanical characterization was done for the evaluation of microhardness, bond strength, and surface roughness. The performance of the developed coating was compared with uncoated steel on slurry jet erosion test rig under accelerated conditions by varying the three parameters, viz. slurry concentration, erodent size, and impact velocity. Ni-40Al2O3 coating was found to be effective for minimizing the erosion rate in comparison with the uncoated steel. Scanning electron microscopy of eroded coatings mainly reveals the brittle type of signature on the coating.

Parametric Optimization of Erosion Behavior of Marble Dust Filled Aramid/Epoxy Hybrid Composite

The aim of present research work is to study the erosive wear response of epoxy based marble dust filled aramid bidirectional fabric-reinforced polymer composite. In this respect the aramid bidirectional reinforced epoxy based composites are fabricated with varying the proportion of marble dust (0, 10 20 and 30 wt.%). Steady state erosion test is performed on different impingement angle to investigate the erosion behavior of composites. The results reveal that erosive resistance of the composites is increasing with incorporation of marble dust and exhibit semi brittle erosion behavior. To increase the performance of erosive wear resistance of fabricated composites L16 orthogonal array design of taguchi method is implemented. Marble dust content, Impingement angle, erodent size and impact velocity are considered as control factors under the set of design experiments. Impact velocity shows significantly effect on the erosion response of marble dust filled aramid fiber reinforced epoxy composite.

Experimental Analysis of Erosive Behavior on Al-SiCP BasedMMC Using Micro Particle (Al2O3) as Erodent

The Effectiveness of the erosion process mainly depends on different properties of the erodent as well as the process parameters. The process parameters such as the impingement angle, Eroded velocity and erodent size have the significant effect on the productivity of the erosion mechanism. To investigate properly on aluminium-based metal matrix composite the erodent chosen was micro Al2O3. A Taguchi based design of experiment was conducted and the effect of the response parameters such as the erosion rate and Signal to Noise ratio (S/N ratio) were studied. It was observed that erosive behaviour of the surface and the mechanisms of material removal mainly depend on the shape and size of the crater formed by the erodent particles which are subjected to variation in shape, velocity & impact angle. Therefore, SEM Analysis was done to find out the surface characteristics and also developed mathematical model for output responses was examined by Analysis of variance (ANOVA) to investigate the suitability of the model. Finally, the cause and effect analyses of various eroded surface characteristics were studied in detail to find out the optimal parameter settings.

Thermo-mechanical and Erosion Wear Peculiarity of Hybrid Composites Filled with Micro and Nano Silicon Dioxide Fillers – A Comparative Study

This article presents the findings on thermo-mechanical and erosion wear characteristics of micro silicon dioxide (SiO2) fillers filled woven glass fiber based vinyl ester hybrid composites (MWGVHCs) as well as nano SiO2 filled woven glass fiber-vinyl ester hybrid composites (NWGVHCs). Wovenglass-vinyl ester based hybrid composites are developed, filled with 5wt.% and 10wt.% of micro and nano SiO2 fillers, respectively. Performance of filler filled composites is compared with the filler less composites. Thermo-mechanical analysis of hybrid composites is done as per ASTM standards. Angles of impact (30°, 45°, 60°, 75° and 90o), impact velocities (30, 55 and 80 m/s) and erodent size of 300, 450 and 600 µm is used for erosion wear test of fabricated composites. Taguchi statistical method is employed for design of experiments to optimize the process parameters. Findings reveal that hybrid composites filled with 10wt% of nano SiO2 filler performed best amongst all the in-class composites. In order to optimize the performance of fabricated composites VIKOR method is also implemented.

Physical, Mechanical, and Erosion Characterization of Palm Leaf Stalk Fiber Reinforced Epoxy Composites Filled with Palm Leaf Stem Stalk (PLSS) Powder

Palm-epoxy hybrid composites were fabricated by incorporating palm leaf stem stalk (PLSS) powder at levels of 0 wt%, 5 wt%, 10 wt%, and 15 wt%. Physical, mechanical, and erosion characteristics of these composites were investigated. Incorporation of filler powder had a positive effect on the hardness and impact strength and a negative effect on the tensile and flexural strength of the composites. The erosion test varied the impact angle (45° to 90°), impact velocity (40 m/s to 80 m/s), and erodent particle size (40 μm to 100 μm). The erosion experiments were statistically designed using Taguchi’s orthogonal arrays. It was found that the erosion rate of palm-epoxy composites decreased with increasing filler powder content, and that the composite filled with 15 wt% PLSS had the highest erosion resistance. The surface morphology of the eroded samples were examined using scanning electron microscopy.

Physico-mechanical and erosive wear analysis of polyester fibre-based nonwoven fabric-reinforced polymer composites

The research work aims to study the physico-mechanical and erosive wear behaviour of polyester fibre-based needle-punched nonwoven fabric mat reinforced epoxy composites. Therefore, the epoxy composites with varying proportion of polyester fibre-based needle-punched nonwoven fabric mat were fabricated and characterized for their physical, mechanical and erosive wear properties. The experimental results indicated that the increase of fibre content enhanced the physical and mechanical properties of the composites. To optimize and improve the erosive wear performance of fabricated composites, the Taguchi method was implemented. For this, L27 orthogonal array was constructed to examine the influence of the five control factors including impingement angle, impact velocity, stand-off distance, fibre content and erodent size. The experimental schedule was carried out in an air jet erosion test rig. The results indicate that the impact velocity emerges as the most significant control factor affecting the erosive wear of fabricated composites. Finally, the possible erosive wear mechanisms were studied by examining the composites eroded surfaces with scanning electron microscopy.

Synthesis and Erosion Wear Analysis of Short Bamboo Fiber Reinforced Epoxy Composites Filled with Ceramic Fillers

Hybrid natural fiber reinforced composites with ceramic fillers has been fabricated. Two ceramic fillers (Alumina and Silicon Carbide) have been used for the synthesis of composites and the samples have been fabricated with hand layup technique. 10% and 20% weight percentage of filler materials have been used for the different sets of composite samples. Erosion wear analysis of these composite samples has been carried out at different impingement angles (30,45,60,75, and 90) with varying impact velocities (48 m/s, 70 m/s, 82 m/s, and 109 m/s) and with varying erodent size (108, 125,150, 180µm). Results for the composites with and without filler have been compared. It has been observed that composites filled with particulate filler shows improvement in wear resistance properties as compared to composites without filler. Among the two fillers, Al2O3 has shown better resistance as compared to silicon carbide. A scanning electron microscope has been used to study the morphology of eroded surfaces and the mode of material removal.

Slurry erosion performance study of HVFS sprayed Ni-20Al2O3 and Ni-15Al2O3-5TiO2 coatings under hydro accelerated conditions

PurposeThis paper aims to cover all the aspects of development, investigation and analysis phases to evaluate the slurry erosion performance of test coatings. The powders having composition of Ni-20Al2O3 and Ni-15Al2O3-5TiO2 were deposited on CA6NM grade turbine steel by using high velocity flame spray (HVFS) technique. The characterization of the coatings was done with the help of SEM/EDS and XRD techniques. Various properties such as micro-hardness and bonding strength of the coatings were also evaluated. Thereafter, these coatings were subjected to an indigenously developed high speed slurry erosion tester at different levels of rotational speed, erodent particle size and slurry concentration. The effect of these parameters on the erosion behavior of coatings was also evaluated. The slurry erosion tests and SEM of the eroded surfaces revealed remarkable improvement in slurry erosion resistance of Ni-15Al2O3-5TiO2 coating in comparison with Ni-20Al2O3 coating.Design/methodology/approachTwo different compositions of HVFS coating were developed onto CA6NM steel. Subsequently, these coatings were evaluated by means of mechanical and microstructural characterization. Further, slurry erosion testing was done to analyze the erosive wear behavior of developed coatings.FindingsThe coatings were successfully developed by HVFS process. Cross-sectional microscopic analysis of sprayed coatings revealed a continuous and defect-free contact between substrate and coating. Ni-15Al2O3-5TiO2 coating showed higher value of bond strength in comparison with Ni-20Al2O3 coating. Under all the testing conditions, Ni-15Al2O3-5TiO2 coatings showed higher resistance to slurry erosion in comparison with Ni-20Al2O3 coatings. Rotational speed, average particle size of erodent and slurry concentration were found to have proportional effect on specific mass loss of coatings. The mixed behavior (brittle as well as ductile) of the material removal mechanism was observed for the coatings.Originality/valueFrom the literature review, it was found that researchers have documented the various studies on Ni-Al2O3, Ni-TiO2 and Al2O3-TiO2 coatings. No one has ascertained the synergetic effect of Alumina and Titania on the slurry erosion performance of Nickel-based coating. In view of this, the authors have developed Ni-Al2O3 and Ni-Al2O3-TiO2 coatings, and an attempt has been made to compare their mechanical, microstructural and slurry erosion characteristics.

A multiple particle impact model for prediction of erosion in carbon-fiber reinforced composites

Material loss and degradation due to erosion remains a major concern in engineering applications for composite materials. A finite element based model has been developed to predict the erosion behavior of unidirectional carbon fiber-epoxy (CFRP) composites subjected to solid particle impacts. In this model, the CFRP plate is subjected to multiple particle impacts at a velocity of 45 m/s, with steel balls as the erodent particles. The Influence of impact angle, erodent particle stream orientation (parallel and transverse to the fiber direction) and erodent particle size has been studied by varying the impact angle from 15⁰–90⁰ and particle sizes considered are of radii 150 µm, 200 µm and 250 µm. The model captures the influence of the erodent particle to particle impacts and the target surface properties by defining two new ratios, kinetic energy ratio, “ηk” and substrate surface property ratio, “ηs”. The cumulative eroded mass predictions are higher for transverse to fiber impact as compared to parallel to fiber impacts. It is also observed that as the erodent size increases the total eroded mass loss increases at all impact angles. The eroded mass predictions obtained from the numerical model compare favorably with the eroded mass results obtained from experimental data reported in the literature.