Erosive Wear Tests Research Articles

Study on corrosion behavior and first-principle analysis of M50 steel in lubricating oil contaminated by salt water

The corrosive wear of M50 steel in lubricating oil contaminated with saline is a form of wear that often occurs within the main shaft bearings of aviation engines carried by aircraft working at sea. In the present paper, the corrosion behavior of M50 steel in lubricating oil contaminated with saline was studied. The open-circuit potential, polarization curve and impedance spectrum were analyzed by rotating electrochemical corrosion wear test. A three-layer interface microscopic molecular model was established with Materials Studio to simulate the dynamic corrosion evolution process of M50 steel self-matching pairs and the adsorption energy was calculated. The results show that the corrosion type is pitting corrosion. With the increase of saline concentration, the corrosion area becomes wider and shallower, and the size of the pitting core gradually decreases. The weight loss of M50 steel increases over time, but the trend slows down, which is also shown in the MS simulation results. Electrochemical tests show that the tribocorrosion of M50 steel is related to load, speed. As the load increases, the corrosion rate decreases. And, as the speed increases, the corrosion rate increases. This has practical significance for extending the understanding of tribocorrosion of M50 steel in marine atmospheric environments.

Erosion Wear Behavior of HVAF-Sprayed WC/Cr3C2-Based Cermet and Martensitic Stainless Steel Coatings on AlSi7Mg0.3 Alloy: A Comparative Study

The paper presents a comparative study of the erosion wear resistance of WC-10Co4Cr, Cr3C2-25NiCr and martensitic stainless steel (SS) coatings deposited onto an AlSi7Mg0.3 (Al) alloy substrate by high-velocity air‒fuel (HVAF) spraying. The influence of the abrasive type (quartz sand or granite gravel), erodent attack angle, thickness, and microhardness of the coatings on their and Al substrate’s wear resistance was comprehensively investigated under dry erosion conditions typical for fan blades. The HVAF-spraying process did not affect the Al substrate’s structure, except for when the near-surface layer was 20‒40 μm thick. This was attributed to the formation of a modified Al-Si eutectic with enhanced microhardness and strength in the near-substrate area. Mechanical characterization revealed significantly higher microhardness values for the cermet WC-10Co4Cr (~12 GPa) and Cr3C2-25NiCr (~9 GPa) coatings, while for the SS coating, the value was ~5.7 GPa. Erosion wear tests established that while Cr3C2-25NiCr and SS coatings were more sensitive to abrasive type, the WC-10Co4Cr coating exhibited significantly higher wear resistance, outperforming the alternatives by 2‒17 times under high abrasive intensity. These findings highlight the potential of HVAF-sprayed WC-10Co4Cr coatings for extending the service life of AlSi7Mg0.3-based fan blades exposed to erosion wear at normal temperatures.

Study on the microstructure and properties of 35Mn2V steel used in oil pipe by salt bath nitriding

Oil pipe is easy to fail due to wear and corrosion during its service, which seriously affects the normal oil production and causes some unnecessary losses，while salt bath nitriding can form a composite infiltration layer through the composite technology on the surface of the workpiece, which can realize the combination of nitriding and oxidation, to achieve the effect of surface strengthening and modification. In this paper, salt bath nitriding is carried out on oil pipe (35Mn2V steel) with different temperature and time, and metallographic test, loose layer grade evaluation, XRD analysis, SEM observation, corrosion wear test, etc. are conducted to study the effect of salt bath nitriding process on the structure and properties of the permeating layer, comprehensively evaluate the quality of the permeating layer, and explore the wear resistance mechanism. The results show that when 35Mn2V is nitrided at 580℃, the infiltration layer mainly consists of oxide film, porous layer, compound layer and diffusion layer, while when it is nitrided at 630℃, the infiltration layer consists of an additional nitrogenous austenite layer. The thickness of 35Mn2V compound layer increases with the increase of nitriding temperature and the extension of nitriding time, and the influence of changing nitriding temperature on the thickness is greater than that of changing nitriding time. After a short time and low temperature nitriding, the phase composition of the infiltration layer is mainly ε-Fe3N and ε-Fe3O4, after a long time and high temperature nitriding, the phase composition is mainly ε-Fe2N and Fe3O4, in which Fe3O4 is formed in the subsequent oxidation process. The degree of loose layer of the infiltration layer increases with the increase of nitriding temperature and the extension of nitriding time. Most of the loose layer grades of the infiltration layer are level 3, and a few are level 2. The degree of loose layer of the infiltration layer is determined by the process of salt bath nitriding, and the subsequent oxidation, ion stabilization and other processes have little influence on it. When 35Mn2V is subjected to corrosion wear test under small load, the friction coefficient of oxide film is small. When the loose layer is worn, the friction coefficient increases obviously. The compound layer is mainly composed of iron-nitrogen compounds, and its friction coefficient is minimal and relatively stable. When the compound layer is worn through, the friction coefficient of the diffusion layer increases.

Tribo-performance analysis of HVOF sprayed Colmonoy-88 using the Taguchi method

The current investigation examines the wear performance of High-Velocity Oxygen Fuel coated Colmonoy-88 coating on SS 304. An L9 orthogonal array design based on the Taguchi fractional factorial method was used to create the erosive wear tests. The impact of three parameters, such as impact velocity (100, 120, and 140 m/s), angle of impact (30°, 60°, and 90°), and test duration (10, 15 and 20 min), on wear performance was investigated by analysis of variance. Results show that the impact angle is the most vital factor for mass loss in both SS 304 and Colmonoy-88, followed by impact velocity and time duration. It was revealed that the maximum wear takes place at 30° impact angle in both specimens. The outcomes of the XRD and EDS analysis show that the Colmonoy-88 has a high chromium content, which provides it with exceptional erosion resistance. The Colmonoy-88 wear mechanism involved inter-splat micro-cutting, lips, crack initiations, and craters caused by fly ash particles at varying impact angles.

Research on erosion wear behavior of NiTi alloy coating fabricated via high-frequency induction heating technology

NiTi alloy is widely used in extreme working conditions due to its pseudoelasticity, shape memory effect and wear resistance. In this study, the NiTi alloy coating (Ni49.8Ti50.2 (at%)) was fabricated by high-frequency induction heating. The coating was well-formed on the surface of cemented carbide YG8 and converted to crystalline after aging treatment. The results of 70h erosion wear experiments carried on the rotary erosion wear test device showing that the erosion wear amount of the coating was reduced by 93 % compared with that of YG8, resulting from the deformation recovery effect. Moreover, the main erosion wear mechanism of the coating was micro-cutting and ploughing. This study can provide technical support and theoretical basis for preparing of NiTi alloy coating and erosion wear resistance.

Effect of filling materials on the tribological performance of polytetrafluoroethylene in different wear modes

AbstractAs it is known, Polytetrafluoroethylene (PTFE) is one of the most preferred polymeric materials for tribological applications. This study investigates the performance of PTFE and its composites under different tribological conditions. The effects of short glass fiber (GF), carbon particle (CP) and bronze particle (BP) reinforcement agents and their hybrid filling with molybdenum disulfide (MoS2) on sliding, erosive and abrasive wear were examined. Sliding tests were carried out with a ball‐on‐disc test apparatus, erosive wear tests were carried out with solid particle erosion and abrasive wear tests were carried out with a scratch test. It has been found that reinforcement agents improve sliding and abrasive wear resistance but worsen the erosion resistance. The hardness and contact angle of the samples were associated with their wear performances. Topographic and morphological analyzes of worn surfaces were performed using optical profilometer and scanning electron microscopy (SEM), respectively, and wear mechanisms were discussed.Highlights Filling materials (glass fiber, carbon particle and bronze particle) increase the adhesion and abrasion resistance of PTFE, while decreasing its erosion resistance. The effect of hybrid addition of MoS2 solid lubricant on wear performances depends on the type of filler. There is a correlation between surface properties (hardness and contact angle) and wear performances. Optical profilometer and scanning electron microscopy were used to examine wear mechanisms.

Experimental investigations with machine learning techniques for understanding of erosion wear in advanced aluminum nanocomposites

This article addresses the significant challenge of erosion wear in aluminum composites, particularly in industries such as automotive, aerospace and energy, where sustained material performance is crucial. The study focuses on the experimental investigation of erosive wear characteristics exhibited by advanced aluminum nanocomposites, utilizing an air jet erosion wear test apparatus. The erosion wear tests were conducted using diverse parameters, such as angles (30°, 45°, 60° and 90°), air pressures (1–4 bar) and a fixed 600-s duration, maintaining a constant sand particle feed rate of 2.0 (g/min) and utilizing stand-off distances of 10, 15 and 20 mm. Surface assessments were conducted using field emission scanning electron microscopy (FE-SEM) and energy-dispersive X-ray spectroscopy (EDS). The results revealed observable specimen wear, particularly at a 45° angle, with wear rates decreasing at higher impingement angles and reaching a minimum at 90°. Notably, the Al-4 wt.%TiC nanocomposites exhibited a 25% improvement in wear resistance compared to the base alloy. Further analysis of eroded surfaces through (FE-SEM) revealed a mechanism involving micro-cutting, plowing and grain pull-out, attributing wear primarily to plastic deformation and crack formation. Evaluating erosive wear results through six machine learning (ML) models demonstrated that gradient boosting regression emerged as the most accurate, achieving an R2 value of 0.97. This highlights the effectiveness of ML in predicting erosion wear rates and offers insights for improving aluminum composite materials in demanding industrial applications.

The solid particle erosion performance of tungsten inert gas yttria-stabilized zirconia - Inconel 625 composite cladding

The yttria-stabilized zirconia (YSZ) - Inconel 625 (IN625) composite cladding was deposited on a stainless steel substrate using a tungsten inert gas welding manipulator to protect it from solid particle erosion. Erosion wear tests were carried out at room temperature according to the ASTM G76-18 procedure. The surface of the tested material was exposed to a jet of alumina erodent particles at impact angles of 30 and 90°, respectively. Scanning electron microscopy images were utilized to examine the morphologies of the eroded surface and the microstructure of cladding. The erosive performance of YSZ - IN625 composite cladding was 3.5 and 2.4 times compared to the substrate at different impact angles. Improved microhardness and fracture toughness resulting from the favourable interaction between the hard ceramic YSZ particles and the IN625 matrix led to the enhanced erosion performance of composite cladding. Micro-cutting and ploughing were the predominant wear mechanisms in the substrate during the solid particle erosion test at a 30° impact angle, whereas the indentation-induced plastic deformation was domi­nant at a 90° impact angle. The results also revealed that the micro-cutting, detached splats and fissures were responsible for the wear in composite cladding at 30 and 90° impact angles.

Effect of pistachio shell particles on mechanical and erosion wear performance of hybrid kenaf/glass polyester composites

The concern for the environmental hazards due to rapid utilization of non-biodegradable resources has persuaded the researchers to develop eco-friendly materials with noble categories of plant-based fibers and fillers. In view of this content, an effort has been initiated in the present work to explore the retrospective effect of PSP (Pistachio shell particles) on both mechanical as well as erosive wear performances of KG (kenaf/glass/kenaf/glass) hybrid polyester laminated composite. The KG laminate with different filler concentration, that is, 0 wt%, 1 wt%, 3 wt%, and 5 wt% were fabricated by using hand-lay-up technique and the mechanical properties of these laminates were determined by performing tensile, flexural and impact tests as per ASTM standard. A higher tensile value of 127.35 MPa with modulus of 7.658 GPa and hardness of 21.35 HV was obtained at 5 wt% reinforcement of PSP filler whereas 3 wt% filler reinforcement responded an optimum flexural strength of 112.42 MPa with modulus of 5.214 GPa and impact strength of 75.59 KJ/m2. To evaluate the wear performance of this laminates against high-speed solid particle, erosion wear test was carried out at different striking velocity and impingement angles. A noticeable reduction of 12.63% in wear rate was found due to increase with concentration PSP filler from 0% to 5 wt%. Further, the η (erosion efficiency) was also found to be limited within the range of 5.94% to 32.98%. From micrographic analysis of the fracture surface, micro-ploughing and micro-cutting actions were found to be most predominant primary wear mechanisms.

Preparation of alumina disc ceramic membrane with enhanced abrasion resistance for dynamic membrane filtration

Although disc ceramic membranes for dynamic filtration provide notable benefits in reducing membrane contamination, enhancing their resistance to erosive wear remains a challenging task. In this work, boehmite sol was employed as an effective additive to establish tightly connections between the membrane particles, and narrow the pore size of ceramic membrane with the increase of boehmite content. Alumina ceramic membranes with 15 wt% of boehmite sol and sintered at 1250 °C exhibited exceptional mechanical strength of 94 MPa, a porosity of 34 %, and an average pore size of 450 nm. Accelerated erosive wear tests were conducted by adjusting variables such as wear time, rotational speed and silica slurry concentration. It was observed that membranes prepared with 15 % boehmite sol exhibited a wear rate only 1/25th that of the without boehmite sol. Furthermore, the membrane displayed a consistent permeate flux of 1510 L m−2 h−1 bar−1 and a retention rate exceeding 99.5 % when filtering slurry containing 150 g/L of solid contents. After an extended duration of dynamic filtration, the flux and retention rate of the disc membrane exhibit a consistent and stable behavior. This disc ceramic membrane demonstrates promising potential for the filtration of suspensions with high solids content.

Surface Characteristics, Properties and Wear Resistance OF TIB2 BASED Hard-Alloy Coatings Obtained by Electrospark Deposition at Negative Polarity on Ti6Al4V Alloy

In the present work, the possibilities of improving the surface properties of titanium alloy Ti6Al4V by electrospark deposition (ESD) at negative polarity were investigated. The coatings were deposited with a TiB2-TiAl-based hard-alloy electrode with nano-sized additives of NbC and ZrO2. The effect of polarity in ESD at low pulse energy (0.01-0.07 J) on the surface roughness, thickness, composition and structure of coatings was studied by profilometric, metallographic, XRD, SEM and EDS methods. In both polarities, dense and uniform coatings were obtained with roughness and thickness, which could be varied by changing the ESD modes within the range Ra=1.5÷4.5 µm, d= 6÷20 µm and microhardness from 9 to 12 GPa, respectively. It was found that the negative polarity coatings obtained are denser and uniform with higher thickness, lower roughness, finer structure, and lower coefficient of friction, and can be successfully used to reduce the surface roughness and defects of 3D printed titanium alloy. Abrasion and erosion wear tests showed that the wear resistance of coated titanium surfaces at both polarities was 2.2 to 3.5 times higher than that of the substrate. Coatings deposited in positive polarity demonstrated higher resistance to abrasive wear, while those in negative polarity are more resistant to erosive wear.

Study on the influence of surface roughness on the erosion characteristics of compressor blades

An aluminum alloy erosion wear test rig was built in this study. The wear rates of the target materials at different surface roughness were measured. An improved Finnie model was developed to predict the wear rate for aluminum alloy plates at different surface roughness. The optimized model was used to analyze the effects of different surface roughness on the erosion wear of the main and splitter blades of the compressor. The study shows that as the surface roughness increases from 1 μm to 60 μm, the size of wear concentration areas of the pressure surfaces of the main and splitter blades spread from the blade height of 80% to 30% and 50%, respectively.

Non-destructive erosive wear monitoring of multi-layer coatings using AI-enabled differential split ring resonator based system

Unprotected surfaces where a coating has been removed due to erosive wear can catastrophically fail from corrosion, mechanical impingement, or chemical degradation, leading to major safety hazards, financial losses, and even fatalities. As a preventive measure, industries including aviation, marine and renewable energy are actively seeking solutions for the real-time and autonomous monitoring of coating health. This work presents a real-time, non-destructive inspection system for the erosive wear detection of coatings, by leveraging artificial intelligence enabled microwave differential split ring resonator sensors, integrated to a smart, embedded monitoring circuitry. The differential microwave system detects the erosion of coatings through the variations of resonant characteristics of the split ring resonators, located underneath the coating layer while compensating for the external noises. The system’s response and performance are validated through erosive wear tests on single- and multi-layer polymeric coatings up to a thickness of 2.5 mm. The system is capable of distinguishing which layer is being eroded (for multi-layer coatings) and estimating the wear depth and rate through its integration with a recurrent neural network-based predictive analytics model. The synergistic combination of artificial intelligence enabled microwave resonators and a smart monitoring system further demonstrates its practicality for real-world coating erosion applications.

Constructing bi-functional Ce-MOF on carbon fiber endowing epoxy coating with excellent anti-corrosion and erosion wear resistance

The limited interfacial combination between CF and polymer matrix caused by the chemical inertness of CF surface greatly restricts the protective capability of carbon fiber reinforced polymer coatings (CFRPCs), which could not effectively resist the impact of external forces, especially in the severe and complicated ocean environment (like deep-sea area and splash zone). Hence, it is the crux to enhance the interface compatibility and interface strength between fiber and resin. Based on the reliable compatibility between imidazole and epoxy as well as the corrosion inhibition effects of cerium-based compounds, a kind of bi-functional metal-organic framework (MOF) called the cerium-imidazole framework (Ce-MI) was constructed on the CFs surface via in-situ growth method to improve the interface compatibility and interface strength of fiber and resin and further increase protective performance of epoxy (EP) coating under the simulated deep-sea area and splash zone. After 168 h immersion under alternating hydrostatic pressure, CF@Ce-MI/EP coating displayed impressive impermeability and anti-corrosion performance, and the interfaces of fiber/epoxy adhered firmly. After the erosion wear test, the volume loss and mass loss of CF@Ce-MI/EP were decreased by 23.77% and 14.80%, respectively, compared with CF/EP. Finally, we discussed the protective mechanism of composite coating to reveal the different processes of interface failure caused by the high pressure and the impact of solid particles, respectively.

Development and erosion wear analysis of polypropylene/Linz‐Donawitz sludge composites

AbstractIn the present investigation, a steel industry waste Linz–Donawitz (LD) sludge was added in different proportions with a polypropylene (PP) matrix and composite specimens were manufactured using the hand layup method. Experiments were performed to study the physical, mechanical, and erosion wear properties of the PP–LD sludge composites. This investigation also includes scanning electron microscopy (SEM), and x‐ray diffraction analysis of filler and composites. The erosion wear tests were carried out by Taguchi's experimental array design, where the effect of five control factors (impingement angle, filler content, erodent size, impact velocity, and erodent temperature) on erosion rate was analyzed. It was observed that filler content is the most influencing factor affecting were rate of the composites. At the maximum filler content of 20 wt%, the compressive strength and hardness increased to 85.71 MPa and 0.643 GPa, respectively. The tensile strength of the composites marginally decreased by 12.97% with the addition of 20 wt% filler. It was further observed that the flexural strength of the neat polymer decreased from 29.23 to 22.98 MPa with the addition of 20 wt% LD sludge. The SEM pictures of the eroded surface exhibited that the material removal is due to micro cracking and crack propagation.Highlights In this study, an industrial waste (LD sludge) is successfully used as a potential filler material in the PP matrix. Physical and mechanical properties of the PP‐LD sludge composites are analyzed. Effects of different parameters like filler content, impact velocity, impingement angle, erodent size and erodent temperature on the wear behavior are studied. Scanning electron microscopy is carried out so that a micro‐examination of the surfaces can be performed, as well as an assessment of the wear derbies.

Impact wear of the Co-based HVOF-sprayed coatings

The dynamic impact test is a tool for investigating the impact wear of the coated samples. In the dynamic impact test, the indenter successively impacts the same place of the sample surface with a constant, well-defined impact load and frequency. This paper focuses on the study of the impact wear of superalloy Co-based HVOF-sprayed coatings, CoCrW and CoCrAlYTaCSi. The impact wear of the coatings was discussed with respect to their mechanical properties and microstructure. The results of the impact wear of the coatings were compared with the results of the erosion wear tests and the sliding/abrasion wear tests. The correlation of impact wear resistance with the resistance of solid particle erosion was confirmed, on contrary to abrasive and sliding wear.

The Corrosion and Wear-Corrosion of the Iron-Base Amorphous Coating Prepared by the HVOF Spraying

In this work, the corrosion behaviors of an iron-based amorphous coating produced by high-velocity oxy-fuel (HVOF) spraying were investigated. Potentiodynamic and potentiostatic polarization and corrosion pin-on-ring (corrosion-wear) tests were conducted to evaluate the corrosive properties of the coating as compared with the 316L substrate. The corrosion behaviors of the 316L substrate and coated sample were tested in 3.5 wt.% NaCl, 1 M HCl, and 0.5 M H2SO4 solutions. In the 3.5 wt.% NaCl and 1 M HCl solutions, the corrosion resistance of the coating was a little inferior or equivalent to that of the 316L substrate after potentiodynamic polarization tests. In the 0.5 M H2SO4 solution, the two tested samples exhibited wide passivated zones in the polarization curves. In such a mild acid, the corrosion resistance of the 316 substrate was superior to that of the amorphous coating, possibly due to the presence of defects in the coating. After potentiodynamic polarization tests, the linkage of initial fine pits into large, deep pores was seen in the corroded 316L substrate. By contrast, extensive corrosion along with preferentially corroded defective sites was seen in the coating. Moreover, the coating exhibited a much higher resistance to corrosion-wear, or low weight loss, in 3.5 wt.% NaCl solution. After the corrosion-wear tests, deep furrows were present in the 316L substrate, whereas a rubbed smooth surface and a corroded zone were seen in the coating. The greater weight loss of the 316L substrate confirmed its poor resistance to corrosion-wear relative to the amorphous coating in 3.5 wt.% NaCl solution.

Microstructure, mechanical properties and fretting corrosion wear behavior of biomedical ZK60 Mg alloy treated by laser shock peening

ZK60 magnesium alloy was treated with laser shock peening (LSP) technology at different laser energy densities. Fretting corrosion wear tests were conducted on the LSP-treated and untreated magnesium alloy samples in simulated body fluid condition. The microstructure, residual stress, surface hardness, tensile strength, and corrosion resistance were also tested to analyze their relationships with fretting corrosion wear behavior. Results showed that a maximum of 73.4% reduction of the fretting corrosion wear volume can be obtained by LSP treatment. The fine grain strengthening and the strain hardening caused by dislocation and twinning, and the compressive residual stress improve the surface hardness, tensile strength, and corrosion resistance at the same time, thus reducing the fretting corrosion wear.

Study of Wear Behavior on AA6061 Reinforced with Hybrid Ceramic Composites through Optimization

This present work uses the three main components for alloying, silver nitrate, aluminium nitride, and titanium diboride. Stir casting was used to make AA 6061 composites with varying weights of 0, 3, 6, 9, and 12%. Microhardness, tensile strength, and compressive strength of produced composites were evaluated. Several wear tests were performed on the composites to measure their resistance to abrasion and erosion. The mass loss was calculated because of wear testing. Conventional and unconventional methods like the Taguchi technique and analysis of variance were employed to study and analyze the abrasive and erosion wear test outcomes to obtain better wear resistance for different weight % of AA 6061 compounds and to investigate the most important input and output characteristics employing the said optimal strategies. Reinforcement percentages were raised to improve mechanical quality.

Erosion-damage-induced vibration response of aero-gas generator rotor system

When a turboshaft engine operates in harsh environments such as deserts, plateaus, and coastal areas, the erosion damage to compressor blades leads to uneven mass distribution of the blade disk of the gas generator and further induces unbalance fault vibration of the rotor system, which seriously endangers helicopter flight safety and mission execution. The vibration characteristics of the rotor system of the gas generator of an aero-turboshaft engine under blade erosion damage are studied innovatively in this paper. The theoretical formula for the blade erosion damage depth is derived. The key parameters for the calculation of the erosion damage to the blades are obtained by combining the particle impact velocity test, Ti-6Al-4 V alloy erosion wear test, and finite element analysis. A new data extraction method for erosion damage based on distribution characteristics and the sparseness–denseness path (DC-SP) is proposed. The unbalance fault mechanism of the rotor system caused by erosion damage is revealed. Using a turboshaft engine as an example, a dynamic model of the rotor system of a gas generator is developed. Unbalance load samples caused by erosion damage are applied, and the whirl trajectory and vibration spectrum characteristics of the rotor system analyzed. The results show that the unbalance magnitude of 1-stage and 3-stage rotor blades caused by erosion damage is 2.33 times and 1.22 times that of 2-stage rotor blades, respectively. The vibration response of the supporting position of the rotor changes with the unbalance phase difference of the rotor blade disk. The vibration amplitude of the supporting position is the lowest when the unbalance phase difference is 0°-180°-180° and is the highest when the unbalance phase difference is 0°-0°-0°. At design speed, the vibration amplitude fluctuation range of the left side of the supporting position is concentrated, whereas that of the right side is large. When the unbalance magnitude increases from 20 to 120 g·mm, the vibration amplitudes of the left and right sides of the supporting position increases by 97% and 263%, respectively.