Erosion Behavior Research Articles

Effect of Si and prolonged time on interfacial morphologies and cavitation erosion behavior of directionally solidified Fe-B alloy in flowing liquid zinc

The effect of Si and prolonged time on interfaces and cavitation erosion behavior of directionally solidified (DS) Fe-B alloy in flowing liquid zinc was investigated. The results show Si enriches in α-Fe intragranular and α/Fe2B boundaries to refine textured grains. DS Fe-B alloy with 2.5 wt%Si exhibits the best cavitation erosion resistance to flowing zinc, which is attributed to formation of alternating distributed Γ-Fe3Zn10 and FeSi and subsequently columnar ζ-FeZn13. Cavitation erosion resistance mechanism of DS Fe-B alloy with 2.5 wt%Si is manifested that Si-induced Γ-Fe3Zn10 and FeSi and the rooting-whisker ζ-FeZn13 layer can inhibit spallation and cracks of Fe2B and products.

Tree internal defects detection method based on ResNet improved subspace optimization algorithm

The erosion behavior of trunk borers leads to the destruction of trunk structure and the formation of internal defects, which significantly impacts the ecological and economic value of trees. Traditional non-destructive testing (NDT) methods are costly and have low resolution, whereas electromagnetic NDT methods are more suitable for high-resolution detection and imaging. However, solving the highly nonlinear electromagnetic inverse scattering problems (ISPs) for small-sized defects with high contrast is challenging. Therefore, this paper proposes an improved subspace optimization algorithm based on a ResNet network called SOM-ResNet. SOM-ResNet incorporates physical principles into deep learning networks by simulating the iterative process of induced current and contrast, thereby enhancing its ability to accurately detect small objects with high contrast. Experimental results demonstrate that SOM-ResNet outperforms single inversion algorithms in detecting complex scatterers with small to medium-sized targets, validating its excellent performance.

Experiments of Main Parameters Affecting the Erosive Behavior of Self-Excited Oscillating Abrasive Water Jets: Length of Self-Oscillation Chamber, Jet Pressure, Abrasive Fluid Velocity, and Abrasive Grain Size.

To enhance the erosion efficiency in traditional abrasive water jet processing, an abrasive water jet processing method based on self-excited fluid oscillation is proposed. Traditional abrasive water jet methods suffer from reduced jet kinetic energy due to the presence of a stagnation layer, which hinders efficient material removal. By integrating a self-oscillation chamber into the conventional abrasive water jet nozzle, the continuous jet is transformed into a pulsed jet, thereby increasing the jet velocity and enhancing the kinetic energy of the process. This modification aims to improve material removal efficiency. Using Ansys Fluent, we simulated the material removal efficiency on workpiece surfaces with varying lengths of self-oscillation chambers. The simulation results reveal that the optimal length of the self-oscillation chamber for maximum erosion is 4 mm. SiC materials were used to evaluate the impact of self-oscillation chamber length (L), jet pressure (P), abrasive flow rate (M), and abrasive grain size (D) on erosion. Experimental results show that the self-oscillation chamber increases erosion depth by 33 μm. The maximum erosion depths recorded were 167 μm when L = 4 mm, 223 μm when P = 16 MPa, 193 μm when M = 80 g/min, and 268 μm when D = 2000 μm. Overall, the self-excited oscillation effect enhances the erosion efficiency of the waterjet by 14%. This study further elucidates the factors influencing erosion behaviors in oscillating abrasive water jet processing.

CAVITATION EROSION BEHAVIOR OF WC–Co COATINGS ON TURBINE STEEL DEPOSITED BY COLD SPRAY

A renowned hard coating material (WC–Co) has the potential to overcome cavitation erosion (CE) in hydromachinery components. Hydro turbines that employ silt-filled water for electricity generation create a lot of metal waste due to erosion and cavitation caused by the particles. There is an urgent need for repair of hydropower components that have undergone damage due to cavitation. In this investigation, tungsten carbide composite coatings were produced on 13Cr4Ni (CA6NM) stainless steel substrates using the cold spray method. In order to create high-quality coatings, nitrogen was used as the propellant gas. The coating microstructures were characterized by EDS, SEM XRD, and microhardness tests. Cold-sprayed WC–Co-based coatings were exposed to enhance the cavitation erosion resistance of CA6NM steel. Cold spray coating prepared with WC-12/17Co powder has shown excellent wear-resistant properties due to higher hardness and lower porosity.

High-temperature erosion behavior of Al2O3 reinforced Inconel625 high velocity oxy-fuel sprayed and direct-aged composite coatings

In this study, Inconel625+30%Al2O3 (IN30AL) blended powders were sprayed on a commercially used boiler steel ASTM SA210 GrA1 using high-velocity oxy-fuel approach (HVOF). The microstructure, mechanical properties and elevated temperature erosion behavior of post-processed coatings and as-sprayed IN30ALcoatings were investigated. The elevated temperature erosion studies on IN30AL coatings both as-sprayed and post-processed were investigated at 900 °C temperature at two impact angles 30° and 90° using standard high temperature erosion test rig. Phase composition, interface of substrate/coating, and morphologies of eroded coatings were examined using x-ray diffraction, x-ray maps, scanning electron microscope, & energy dispersive spectrometer techniques. Compared with the as-sprayed IN30AL coatings, the heat-treated coatings have refined microstructure, better mechanical properties which improve the elevated temperature erosion resistance of IN30ALcoatings.

Effects of molten silicate reactivity on high temperature erosion behavior of plasma sprayed Yb2Si2O7-based EBCs

Particulate/debris damage caused by ingestion of calcium magnesium aluminosilicates (CMAS) hinders the durability of environmental barrier coatings (EBCs) used to protect SiC-based ceramic matrix composite components in next generation gas turbine engines. Similarly, ingestion of any debris in the engine can lead to mechanical damage and recession of coatings due to particulate erosion. Investigating particulate interactions at relevant engine conditions is crucial for determining limiting mechanisms in the operating lifetime of EBCs. This study assessed the effects of extrinsic phase formation and microstructural changes due to CMAS interactions on the erosion durability of Yb2Si2O7-based EBCs in a laboratory-scale combustion facility. CMAS exposures and erosion testing were carried out at 1316°C. Using 60 μm Al2O3 particles as the erodent material, the effects of CMAS loading on erosion durability at various impingement angles were evaluated.

Erratum to: Solid Particle Erosion Behaviour of Laser Sintered Heat Treated Ti–6Al–4V Alloy

Erratum to: Solid Particle Erosion Behaviour of Laser Sintered Heat Treated Ti–6Al–4V Alloy

Reliability Assessment of Gored Elbow in Erosive Two-Phase Flow with Sand Particles

Erosion, a major threat to the safety and reliability of piping components, can significantly impact their integrity and functionality. This study employs computational fluid dynamics (CFD) to systematically investigate the erosion behavior of four elbow designs (standard 90-degree elbow, 18-degree gored elbow, 22.5-degree gored elbow, and 30-degree gored elbow) subjected to multiphase air-sand and water-sand flows. Our primary objective is to identify the optimal elbow design that effectively mitigates erosion and enhances the safety and reliability of piping systems. Our findings reveal that the 22.5-degree gored elbow exhibits significantly lower erosion rates compared to other designs, particularly in air-sand flows, making it the superior choice for reducing erosion by up to 32% compared to the standard elbow. However, the standard 90-degree elbow demonstrates greater erosion resistance in water-sand flows. This research contributes valuable insights for selecting the optimal elbow design in multiphase flow, ultimately enhancing the design and longevity of piping systems.

Microstructural transformation and corrosion–cavitation behavior of ultrasonic nanocrystal surface modified nickel aluminum bronze (NAB)

In this study, nickel–aluminum bronze (NAB) is optimized by ultrasonic nanocrystal surface modification (UNSM), and its surface microstructural evolution, surface hardness, electrochemical corrosion behavior, and cavitation erosion behavior are investigated. The potentiodynamic polarization curves and electrochemical impedance spectra before and after UNSM treatment of NAB are measured using a typical three-electrode system. The cavitation erosion process is simulated through the vibration of ultrasonic waves underwater, and the cavitation erosion resistance performance of various specimens is evaluated. UNSM significantly refines the coarse and heterogeneous multi-phase structure of the cast NAB, providing a relatively uniform and dispersed structure. Simultaneously, severe plastic deformation rapidly increases micro-strains on the NAB surface, which effectively improves its surface hardness from 211 to 360 Hv. After UNSM treatment, the corrosion potential increases slightly; and the passivation potential and current decrease considerably, dropping from 207 to 103 mV and from 5.23 to 2.41 mA/cm2, respectively. This is primarily because of the slowdown of selective-phase corrosion and the uniform formation of an oxide film. Additionally, UNSM parameters affect corrosion potential by regulating surface roughness. A smoother surface corresponds to a higher corrosion potential at the same load. UNSM treatment significantly improves the cavitation corrosion resistance of NAB, primarily because an increase in hardness and uniform distribution of structure effectively slows the speed of crack formation and propagation, which is a result of the synergistic improvement of mechanical and corrosion resistance properties.

Effects of W element on the microstructure, wear and cavitation erosion behavior of CoCrFeNiMnWx high entropy alloy coatings by laser cladding

CoCrFeNiMnWx (x = 0, 0.5, 1, 1.5, 2) high entropy alloy (HEA) coatings were prepared on the surface of 304 stainless steel (304 SS) by laser cladding technology. The effects of W addition on the microstructure, microhardness, friction and wear properties, and cavitation erosion (CE) resistance of the coatings were thoroughly studied. The results show that the phase structure of the CoCrFeNiMnWx HEA coatings exhibits FCC structure, and the microstructure is typical dendrite (DR) and inter-dendrite (ID) morphology. With the increase of W content, the average grain size of CoCrFeNiMnWx HEA coatings gradually decreases. The microhardness of CoCrFeNiMnWx HEA coatings increases first and then decreases due to the brittle cracking caused by the excessive addition of W element. The wear resistance of CoCrFeNiMnW1 HEA coating is the highest, and its wear rate is much lower than that of CoCrFeNiMn HEA coating without W addition. The wear mechanism of CoCrFeNiMnWx HEA coatings is mainly adhesive wear, abrasive wear and oxidation wear, and the fatigue wear mechanism appears on CoCrFeNiMnW2 HEA coating. In addition, CoCrFeNiMnW1 HEA coating displays the highest CE resistance, and its mass loss after CE in 3.5 wt%Nacl solution is lower than that of CoCrFeNiMn HEA coating. The appropriate addition of W element can effectively improve the resistance to wear and CE of CoCrFeNiMnWx HEA coatings, showing a great potential in improving the service lifespan of overflow parts in marine environment.

Correlative characterization of plasma etching resistance of various aluminum garnets

AbstractPlasma etching is a crucial step in semiconductor manufacturing. High cleanliness and wafer‐to‐wafer reproducibility in the etching chamber are essential in order to successfully achieve nanometer‐sized integrated functions on the wafer. The trend toward the application of more aggressive plasma compositions leads to higher demands on the plasma resistance of the materials used in the etching chamber. Due to its excellent etch resistance, yttrium aluminum garnet Y3Al5O12 (YAG) is starting to replace established materials like SiO2 or Al2O3 in this kind of application. In this study, reactive spark plasma sintering (SPS) was used to manufacture highly dense YAG ceramics from the respective oxides. In addition, yttrium was replaced with heavier lanthanoids (Er, Lu), intending to investigate the role of the A‐site cation in the garnet type structure on the plasma erosion behavior. The produced materials were exposed to fluorine‐based etching plasmas mimicking the conditions in the semiconductor manufacturing apparatus and the erosion behavior was characterized by atomic force microscopy (AFM), secondary ion mass spectrometry (SIMS), transmission electron microscopy (TEM), and profilometry. The induced chemical gradient in the samples is limited to a few nanometers below the surface, which makes its characterization challenging. For advanced analysis, we developed a correlative characterization method combining SIMS and scanning TEM (STEM)–energy‐dispersive spectroscopy (EDS) enabling us to examine the structural and chemical changes in the reaction layer locally resolved. In the case of lanthanoid aluminates, an altered reaction layer and reduced fluorine penetration compared to YAG were found. However, a correlation between the characteristics of the induced chemical gradient and the determined physical erosion rates was not evident.

Simulation of Elbow Erosion of Gas–Liquid–Solid Three-Phase Shale Gas Gathering Pipeline Based on CFD-DEM

Shale gas gathering pipelines often contain liquid water and solid sand in the early stage of production, which leads to the failure of pipeline components easily under the action of gas–liquid–solid three phases. A computational fluid dynamics (CFD) model based on the fluid volume method (VOF) and discrete element method (DEM) was established to study the flow law of gas–liquid–solid three-phase flow in the elbow of shale gas gathering pipeline and the erosion law of the inner surface of the elbow was studied by coupling the Oka erosion prediction model. By comparing the experimental results of erosion damage of the elbow, it is found that the model established can well predict the erosion characteristics and erosion amount under the action of three phases. Combined with the field pipeline parameters and operating conditions, the paper further simulates the elbow erosion behavior under relevant working conditions. The results show that the particles rotate clockwise from the outer wall of the pipe through the bottom of the pipe when passing through the elbow under the action of gas and water phases. When the gas velocity increases, the particles at the elbow mainly gather at the bottom of the elbow and the wall of the outer arch. When the water content increases gradually, the particles gathered on the outer arch wall of the elbow move along the outer arch wall of the elbow and face the inner arch surface gradually, and the erosion area is mainly concentrated on the outer arch wall of the elbow and the outlet horizontal pipe. Under the condition of the liquid phase, the movement characteristics of the water phase and particles in the elbow of the gas gathering pipeline and the erosion characteristics of the pipeline surface are obviously different from those under the condition of the gas–solid two-phase. The model and simulation results established in this paper provide a reference for the erosion damage protection of shale gas gathering pipeline elbow.

Corrosion and erosion behaviour of TiC-TiB2 reinforced epoxy coatings

ABSTRACT This research investigates the impact of incorporating titanium carbide (TiC) and titanium diboride (TiB2) particles into epoxy coatings to enhance corrosion and erosion resistance. The targeted particles were synthesised by subjecting boron and titanium carbide powders to mechanical alloying for a duration of 20 hours. X-ray diffraction (XRD) analysis confirmed the successful formation of titanium diboride and titanium carbide particles. Subsequently, ceramic particles were integrated into the epoxy at concentrations of 0, 5, 10, and 15 wt.%, and the resultant coatings were applied to steel samples through an immersion method. Electrochemical impedance spectroscopy tests on the samples demonstrated a positive influence of TiC + TiB2 particles on enhancing the corrosion resistance of the coatings, with the 15 wt.% concentration exhibiting superior corrosion resistance compared to other formulations. Employing the Box–Behnken method, 13 samples were designed and subjected to erosion testing. The findings revealed that the coating containing 15 wt.% TiC + TiB2 particles exhibited the lowest erosion rate. Moreover, an increase in the speed and angle during the erosion test correlated with a rise in the erosion rate.

Erosion, deposition and breach evolution of landslide dams composed of various dam material types based on flume tests

The accurate and rapid prediction of breach outflow rates of landslide dams is crucial for effective risk assessment and mitigation strategies. However, challenges arise due to the complexities associated with breaching mechanisms. In this study, 12 flume tests were conducted on landslide dams composed of various material types, including fine-grained, coarse-grained, well-graded, and gap-graded materials, each with two dry densities. This study comprehensively investigated erosion, deposition, and breach evolution, providing the foundation for the development of breach evolution models. A comprehensive logic diagram, focusing on shear stress and grain size distribution, was proposed to forecast the failure modes of landslide dams. The study also suggested a method to assess the longitudinal breach evolution based on the prediction of the Erosion Point (EP) and Deposition Point (DP), and to assess the lateral breach evolution by considering both steep and gentle breach side slopes. Our findings indicate that fine-grained materials undergo layer erosion, coarse-grained materials remain stable, well-graded materials develop erosion pits, and gap-graded materials are prone to piping. The existence of an interface can result in piping channels, even when the overall hydraulic gradient is insufficient to initiate piping. Incorporating the longitudinal slope angle and its influence on both driving and resisting forces into the traditional erosion rate equation can significantly enhance its accuracy, especially when coarse particles are present. Coarse particles play a pivotal role in erosion and deposition behavior and reshaping the breach evolution as the initiation of coarse particles is dominated by rolling instead of slipping in fine particles. Deposition on the downstream slope of a dam can significantly influence the longitudinal breach process, leading to changes in the downstream topography and grain size distribution. The proposed method for assessing longitudinal breach evolution unifies the previous methodologies by predicting the positions of EP and DP based on erosion and deposition.

Erosion behaviors and mechanisms of Ti3AlC2 material under arc discharge in various mixed atmospheres

The present study establishes an experimental platform for investigating arc erosion and explores the erosion characteristics of Ti3AlC2 material under a voltage of 10 kV in SF6/N2, SF6/CO2, and N2/CO2 environments. Our findings reveal that the arc energy and duration exhibit a gradual increase in the sequence of SF6/N2, SF6/CO2, and N2/CO2, while the breakdown strength decreases. Scanning electron microscopy (SEM) and a three-dimensional laser confocal microscope were employed to observe uneven erosion morphology. Additionally, high-speed camera footage captures the arc bending and drifting phenomenon caused by Rayleigh-Taylor instability between the arc and gas. X-ray diffraction (XRD), Raman spectroscopy, and X-ray photoelectron spectroscopy (XPS) analysis were utilized to characterize the composition of eroded surfaces. Erosion models were proposed for each mixed atmosphere along with comprehensive discussions on their underlying mechanisms. This work expands the application scope of MAX phase materials while providing a theoretical foundation for designing electrical contact materials.

Cavitation erosion-corrosion properties of as-cast TC4 and LPBF TC4 in 0.6 mol/L NaCl solution: A comparison investigation

In this work study, a comparative analysis was undertaken to investigate investigation into the cavitation erosion (CE) and corrosion behavior of laser powder bed fusion (LPBF) TC4 and as-cast TC4 in 0.6 mol/L NaCl solution. Relevant results indicated that LPBF TC4 revealed a rectangular checkerboard-like pattern with a more refined grain size compared to as-cast TC4. Meanwhile, LPBF TC4 surpassed its as-cast counterpart in CE resistance, demonstrating approximately 2.25 times lower cumulative mass loss after 8 h CE. The corrosion potential under alternating CE and quiescence conditions demonstrated that both LPBF TC4 and as-cast TC4 underwent a rapid potential decrease at the initial stages of CE, while a consistent negative shift in corrosion potential was observed with the continuously increasing CE time, indicative of a gradual decline in repassivation ability. The initial surge in corrosion potential during the early CE stages was primarily attributed to accelerated oxygen transfer. As CE progressed, the significant reduction in corrosion potential for both LPBF TC4 and as-cast TC4 was attributed to the breakdown of the passive film. The refined and uniform microstructure in LPBF TC4 effectively suppresses both crack formation and propagation, underscoring the potential of LPBF technology in enhancing the CE resistance of titanium alloys. This work can provide important insights into developing high-quality, reliable, and sustainable CE-resistant materials via LPBF technology.

Towards sustainable composites: Evaluation of mechanical properties, erosion behavior and applications of natural fiber-epoxy composites

Sustainable production and consumption, carried to materials and engineering applications, translates to a need for recyclable, reusable, and/or biodegradable materials. With its lower cost, lighter weight, and less carbon footprint compared to traditional glass and carbon fiber composites, natural fiber-reinforced composites are drawing more attention from the scientific community and the industrial sector. The natural fiber’s high variability and relatively inferior mechanical properties necessitate comprehensive characterization for accurate evaluation of their properties and fitness for different applications. In this research, various locally grown natural fibers (Flax, Jute, and Luffa) were sourced, characterized, and used to synthesize natural fiber-reinforced epoxy composites. The tensile, flexural, impact properties, and erosion resistance of the composites was evaluated. Compared to the other natural fiber composites, the Jute-Epoxy composite achieved the highest tensile strength and tensile modulus with 31 MPa and 4.8 GPa respectively; Jute-Epoxy also achieved the highest flexural strength and flexural modulus, with and 60 MPa and 2.4 GPa respectively. This superior mechanical performance is due to the relatively high strength of the Jute fiber and its high adhesion to the matrix, which is supported by fractographic evidence. Luffa-Epoxy composites in general had the lowest properties of all the tested materials. The erosion test results showed that the Jute-Epoxy composites had the highest erosion resistance of all the tested materials; with 30% more erosion resistance compared to glass-fiber epoxy composites. Based on the experimental results of the investigation and similar previous research, the current and potential applications of natural fiber composites were discussed.

Study on high-temperature erosive wear behaviour, surface roughness and scratch resistance of NiCrAlY-based composite coating

Study on high-temperature erosive wear behaviour, surface roughness and scratch resistance of NiCrAlY-based composite coating

Erosive wear and topographical study of zinc-aluminum based composite reinforced with in-situ formed ZrB2 particles

The present study deals with the erosive wear behaviour of a zinc-aluminum (ZA) alloy and composite in the slurry medium. The effects of reinforcement of zirconium diboride (ZrB2) particles in ZA alloy, as well as the impingement angle and duration of erosion wear responses have been studied. The slurry composition was prepared with 1.5 L of water and 500 g silica of a size range of 350–450 μm. The erosion tests are performed at a speed of 600 rpm for varying durations (20–80 h) and impingement angles (30°–90°). The erosive wear responses of the samples have been analyzed in terms of distinct features of their micro constituents like ZrB2 and the material removal mechanism in a prescribed set of conditions. A significant decrease in composite erosion compared to ZA alloy has been observed. With increased duration, both alloy and composite show increased erosive wear. Obtained results revealed that the composite shows 60–80 % less erosive wear than ZA alloy on operating conditions. The optimum results in wear have been observed at 45° for alloy and 60° for composite. Investigating topographical aspects using scanning electron microscopy and atomic force microscopy revealed that ZrB2 reinforcements resulted in smoother topography and reduced erosive wear.

Cavitational Erosion Behavior of a Biodegradable Alloy from the Zn-Mg System for Biomedical Applications

Zinc and magnesium are known to be biocompatible metals. For this reason, current technologies seek to build parts to be implanted in various places to help the human body. Among these are those in the blood circulatory system, such as the stars and valves at the heart, which aim to increase the life span of the hydrodynamic shocks of the blood circulatory system, in order to prevent heart attacks, respectively the bursting of various vessels that can be life-threatening. Studies in the field of flow show that even in the human body there are manifestations of cavitational type, as a result of pressure variations, with decrease below that of vaporization and then increase. Starting from these findings, the paper presents the results of the cavitation tests, carried out on the bicocompatiobil ZnMg alloy, created in Politehnica University of Bucharest laboratories. The objective is a new and future one that will lead to the realization of valves for the heart, or stars, that can withstand the shocks produced by the implosions of the cavitational bubbles in the blood. For this purpose, microstructural investigations are performed, mechanical properties are analysed and the behavior and resistance to erosion generated by vibrating cavitation are studied, according to the reference standard ASTM G32-2016. The results, compared to those of pure zinc, show that this alloy is a solution for building biocompatible components that can serve cardiac people, in order to reduce the harmful effects of the blood circulatory system.