Erosive Wear Behavior Research Articles

A study on the effect of nanoclay addition on the erosion wear characteristics of S-glass/sisal reinforced hybrid polymer composites

This study investigated the erosion wear behaviors of S-glass (G) and sisal (S) fibers reinforced with nanoclay (NC). Samples were fabricated using epoxy and polyester matrices through a hand lay-up process, consisting of four fiber layers (GSSG) with varying NC weight percentages (2, 4, 6 wt.%). Tests were conducted at room temperature using angular-shaped silica sand erodents impacting at 148 m/s at angles of 30°, 60°, and 90°. The results showed that erosion wear was highest at a 60° impact angle, indicating a semi-ductile nature of the composites. The hybrid NC polymer composite with 2 wt.% NC exhibited the highest erosion wear resistance at a 90° impingement angle. A significant reduction in wear rate was observed at 2 wt.% NC, with a 43% decrease in Polyester/GSSG and an 18% decrease in Epoxy/GSSG when comparing 60° and 90° impact angles. Polyester-reinforced composites demonstrated superior wear resistance compared to epoxy-reinforced ones. SEM analysis of the eroded surfaces revealed the wear mechanisms involved. These composites are anticipated to be used as high-speed machinery or aggressive environments, enhancing resistance to erosion wear.

Optimization of erosion performance of biomass and pet waste based composites using artificial neural network

The determination of the potentiality of renewable energy resources holds significant importance, with biomass emerging as a crucial alternative for both energy and material needs. Consequently, predicting the mechanical properties of these resources has become a focal point. This study focuses on the analysis of fundamental products resulting from the pyrolysis process, specifically char, extracted from Polyethylene terephthalate (PET) Char, Cashew biochar, and Sugarcane biochar and examining erosion performance of polyester composites. The polyester composites subjected to erosion tests to determine their wear resistance at various impact angles. Among the studied composites, those including cashew biochar shown enhanced erosion resistance, with the least erosive wear at a 60° impact angle. The investigation aims at optimizing the erosion performance of these biomass-based composites using an Artificial Neural Network (ANN) model. The ANN was trained to predict erosive wear behavior using input factors as biochar type, filler content, and impact angle. The model effectively found ideal conditions for decreasing wear, demonstrating the potential of Cashew biochar-filled composites for applications needing high erosion resistance. This work sheds light on the successful usage of biochar fillers in improving the durability of polyester composites, presenting a sustainable alternative for materials engineering.

Corrosion resistance and wear behavior of CoCrFeNiMn@Gr high entropy alloy-based composite coatings prepared by laser cladding

In this study, we utilize laser cladding to apply a CoCrFeNiMn HEA with 2 wt.% few-layer graphene (Gr) coating onto the surface of Q235B mild steel. Alcohol stirring method was used for HEA and Gr preparation of composite powder. Raman spectroscopy and energy dispersion spectroscope (EDS) indicate the successful mixing of HEA and Gr powders, with Gr adhering to the surface of the HEA powder in a lamellar structure. The X-ray diffraction (XRD), scanning electron microscope (SEM), EDS, and Electron backscatter diffraction (EBSD) analyses revealed that grain refinement and the formation of fine carbide-hard phases in the HEA/Gr coating improve microhardness and wear resistance. The average Schmidt factors of the coating decreased from 0.47 to 0.45 with the addition of Gr, indicating enhanced resistance to plastic deformation and anisotropy. Nanoindentation experiments demonstrated that the HEA/Gr coatings exhibit superior resistance to plastic deformation, effectively enhancing the coating’s durability against spalling under stress and wear conditions. The microhardness of the HEA/Gr coating increased by 99.25%, and the wear rate decreased by 86.31% compared to the HEA coating alone. The open circuit potential (OCP), linear polarization curve, Tafel curves, electrochemical impedance spectroscopy (EIS), and Mott-Schottky tests all indicated that the HEA/Gr coating possesses superior corrosion resistance. X-ray Photoelectron Spectroscopy (XPS) results suggest that the passivation film of the HEA/Gr coating, which contains more oxides and less hydroxide, is more protective and denser, thereby slowing the corrosion rate.

An investigation on the mechanical, thermal and tribological properties of newly developed polyester composites made with Pistachio shell particles for industrial applications

The drive for sustainability and addressing environmental concerns has led to the productive use of bio-waste. This research investigates the potential of pistachio (Pistacia vera) nut shell particles as a novel filler in polyester composites. The study explores the use of these nut shells as a reinforcing material in polyester-based composites to evaluate their mechanical and thermal properties. Pistachio shell particles (PSP) are mixed with polyester resin in varying weight fractions (0%, 1%, 3%, and 5%) to create a new type of composite. The impact of filler content, impingement angle and striking velocity on the erosive wear behavior of these composites are also studied. The mechanical results for the composites revealed that incorporating PSP filler resulted in the maximum rise in tensile (96.61%), impact strength (66.66%), micro-hardness (52.94%), under loading of 5 wt% of PSP filler. However, the composite with 3 wt% of PSP filler, resulted in the maximum rise of flexural strength (135.65%) and flexural modulus (45.28%). Results showed that, composites with 5 wt% of PSP filler exhibited superior erosive resistance. An optimal parameter setting is determined for minimum erosion rate and subsequently validated by conducting confirmation experiment as per Taguchi methodology. Different modes of material removal, wear craters and other qualitative attributes are examined by a scanning electron microscopy during erosion experiment of the samples. Thus, the utilization of agro/food wastes in the development of bio-based products holds significant potential and offers the possibility of replacing conventional materials in various industrial applications.

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.

Investigating the erosive wear characteristics of AISI 420 martensitic stainless steel after surface hardening by boriding

Erosive wear degrades industrial components, causing surface deterioration and material loss. Understanding and mitigating this wear enhances component longevity and efficiency. Little research has been conducted to investigate the influence of particle angle, speed, and concentration on boronized surfaces. Therefore, in this study, the erosive wear behaviors of raw and boronized AISI 420 martensitic stainless steels were investigated. The samples were subjected to erosive wear testing using SiO2 abrasive particles with impact velocities of 2, 4, and 6 m/s, impact angles of 30°, 60°, and 90°, and concentration values of 5%, 10%, and 15% by weight in an abrasive sand slurry environment. Experimental runs were designed using the Taguchi L9 method. The wear test results were analyzed in terms of mass loss, surface roughness, and temperature change of the boronized and raw AISI 420 samples before and after the test. The results showed that the impact speed and concentration were statistically significant parameters compared with the impact angle, which had a negligible effect. Furthermore, with increasing impact speed and concentration, all measured responses increased in both sample groups. The surface roughness values and mass loss increased by lower margins for the boronized samples (58.40% and 188.49%, respectively) compared to those of the raw samples (61.40% and 254.38%, respectively). This study demonstrates the potential of boriding as a surface treatment technique for enhancing the erosive wear performance of martensitic stainless steels, which require improved durability and longevity of materials subjected to erosive environments.

Influence of Ni content on electrochemical corrosion and tribological behavior of Cu-10Sn coatings by laser cladding

In this work, Cu-10Sn-xNi (x = 0, 3, 6, 9, and 12 wt%) alloy coatings were prepared using laser cladding technology. The influence of Ni content on the phase composition, microstructure, crystallographic characteristics, microhardness, electrochemical corrosion, dry sliding wear and corrosive wear behavior of the coatings were studied. The results indicated that the coatings formed good metallurgical bond with the substrate. The coatings were composed primarily of the α-Cu matrix and small γ precipitates. The Ni element effectively reduced component segregation, and with the increased of Ni content, the grain size in the coating was significantly refined, resulting in fine equiaxed grains. Under the effect of fine grain strengthening, the Cu-10Sn-12Ni (C12NS) coating achieved a higher microhardness of approximately 222.9 ± 5.3 HV0.2. In the electrochemical corrosion test, the increased in the number of grain boundaries significantly reduced the corrosion resistance of the Cu-10Sn-xNi coatings. The Cu-10Sn-6Ni (C6NS) coating exhibited excellent corrosion resistance, with an Icorr of only 1.37 μA/cm2. The results of the dry sliding wear test showed that under the influence of the hardness gradient between the hard precipitate phase and the soft matrix of the coating, the C6NS coating achieved satisfactory wear resistance with a specific wear rate of 3.30 × 104 μm3/Nm. Meanwhile, due to the good corrosive resistance, the C6NS coating showed the best tribological performance in 3.5 wt% NaCl environment, and the specific wear rate was 1.58 × 104 μm3/Nm.

Influence of pH value on erosive wear of 3D-printed polylactic acid for multiphase flow

Abstract Slurry erosion presents a critical challenge in hydrocarbon and cement processing industries, as well as in abrasive water jet cutting systems, leading to diminished operational efficiency and elevated maintenance costs. This study investigates the erosive wear behavior of Poly-Lactic Acid (PLA) fabricated with varying infill microtextures—zigzag, concentric, and grid—under diverse pH conditions (2.73, 7.75, and 10.15) using garnet particles as the erodent. The results demonstrate that optimal operational conditions for PLA are achieved with a grid microtexture, a pH of 7.75, and a 325 μm erodent size. Conversely, the most severe wear occurs under a pH of 10.15, a 600 μm erodent size, and a zigzag microtexture. The grid microtexture is the most effective in minimizing erosion, while the zigzag pattern shows a 16.68% increase in wear when compared to the grid microtexture. Additionally, a shift from a slightly basic to a highly acidic environment increases wear by 1%, whereas a transition to a highly basic environment leads to a 32.6% increase in erosion within the grid microtexture. The study highlights the significant contributions of infill microtexture (64%), erodent size (23.7%), and pH value (11%) to the overall erosion rate.

Investigating the solid particle erosion behavior of H3BO3 / B2O3 / SiO2 / Al2O3 reinforced glass fibre/epoxy composites and parametric evaluation using artificial intelligence

In this experimental study, the erosion wear behavior of glass fibre-reinforced (GF) composite materials was examined according to ASTM G76–95. Pure/GF reinforced epoxy composite (EP) materials were chosen as the main test sample. Boric Acid (H3BO3), Borax (B2O3), Silicon Dioxide (SiO2), and Aluminium Oxide (Al2O3) were added to the resin as reinforcement at a rate of 15% by weight. The erosion wear rate was investigated with various impingement angles (30°, 60°, and 90°), impact velocities (≈23, 34, and 53 m/s), alumina abrasive particle sizes (≈200 and 400 μm), and fibre directions (0° and 45°). Neural network models were employed effectively to predict the influence of the reinforcements on erosive wear rate. The erosive wear rate indicated that Al2O3 added GF/EP exhibited the most anti-erosive characteristics followed by silicon dioxide GF/EP and pure GF/EP however, the anti-erosive nature of GF/EP deteriorated with the addition of Borax and Boric Acid.

Microstructure, corrosive wear and electrochemical properties of Al2O3 reinforced FeAl coatings by laser cladding

PurposeThis study aims to investigate the influences of Al2O3 mass fraction on the corrosive wear and electrochemical behaviors of FeAl–xAl2O3 coatings.Design/methodology/approachFeAl–xAl2O3 coatings were prepared on S355 steel by laser cladding to improve its corrosive wear and electrochemical properties.FindingsThe average coefficients of friction and wear rates of FeAl–xAl2O3 coatings are decreased with the Al2O3 mass fraction, and the Al2O3 plays a positive role in the corrosion wear resistance. Moreover, the charge transfer resistance of FeAl–xAl2O3 coatings is increased with the Al2O3 mass fraction, showing the FeAl–15%Al2O3 coating has the best corrosion resistance. The findings show the corrosion resistance of FeAl–15%Al2O3 coating is the highest among the three kinds of coatings.Originality/valueAl2O3 was first added into FeAl coatings to further improve its corrosive wear and electrochemical properties by laser cladding.

Characterization and erosion wear behavior of Ni-13%WC8Co microwave clad on AISI-316 steel

Characterization and erosion wear behavior of Ni-13%WC8Co microwave clad on AISI-316 steel

Experimental study on slurry erosion wear behaviour of 2205 duplex stainless steel through integrated Taguchi approach and artificial neural network

Slurry erosion due to particle entrainment poses a significant threat to slurry handling components, leading to reduced performance and shorter service life. The ferritic-austenitic microstructure of 2205 duplex stainless steel (DSS) offers resistance to erosion and corrosion in harsh environments. This study investigated the slurry erosion wear response of 2205 DSS, focusing on parameters, such as: angle of impingement, impact velocity, slurry concentration, erodent size, and stand-off distance. A Taguchi experimental design approach, along with analysis of variance (ANOVA), was employed to design the experiments and identify the most significant factors. ANOVA results revealed that impact velocity and slurry concentration were the most influential parameters affecting mass loss, while erodent size and impact velocity significantly influenced surface roughness. Additionally, an artificial neural network model was used to estimate output responses, and the model's predictions were compared with experimental results. The surface and sub-surface characteristics of the eroded samples were analysed using X-ray diffraction, microhardness testing, and optical profilometry. The material removal mechanisms were studied using scanning electron microscopy, revealing ductile erosion behaviour in 2205 DSS. Micro-cutting, ploughing, lip formation, and indentation were identified as the primary methods of material removal in 2205 DSS.

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.

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.

Research on corrosion wear behavior of connecting bearings made of different steels in suspension bridge suspension system

Research on corrosion wear behavior of connecting bearings made of different steels in suspension bridge suspension system

INFLUENCE OF COOLING MEDIUM ON MICROSTRUCTURE AND MECHANICAL PROPERTIES IN FRICTION STIR PROCESSING OF MAGNESIUM ALLOY — A REVIEW

Friction stir processing (FSP) is used for changing the microstructure and material properties improvement. In modern years, special attention is exposed by governing the temperature level, and is applied by various coolants spraying on the top surface of the sample during FSP. This review paper explores the impact of several cooling mediums such as normal water, cold water, hot water, and cryogenic on the temperature distribution, grain refinement, mechanical characteristics, and superplastic deformation behavior of FSP using various grades of magnesium (Mg) alloys. It also includes the corrosion rate and wear behavior of FSP on Mg alloys. Through the systematic review, it has been observed that refined grains were formed and the generation of intermetallic compounds was suppressed after FSP in underwater and cryogenic conditions, leading to a notable increase in strength. The higher tensile strength and elongation are exhibited while using cryogenic compared to water medium. This is due to a rapid cooling process, where the high temperature was short for the newly-formed grains to fully develop. This review not only concludes the key findings of the preceding research but also suggests future recommendations.

Tribological properties and solid particle erosion wear behavior of Al2O3-13 wt%TiO2/Al2O3-PF composite coatings prepared on resin matrix by supersonic plasma spraying

Resin materials feature exceptional physical properties and inexpensive cost, but unfavorable surface characteristics, such as low wear resistance and poor erosion wear performance, render them tough to satisfy greater demands. The potential option is to prepare supersonic plasma sprayed Al2O3-13 wt%TiO2/Al2O3-phenolic resin (AT13/Al2O3-PF) coating on the surface of the resin matrix. AT13 feedstocks are classified into two types: Al2O3-13 wt%TiO2 powder prepared by the agglomeration granulation process (AT13-1) and the mixture of spherical Al2O3 and TiO2 (approximately 13 wt%) powder (AT13-2). The effect of component dispersion on mechanical and tribological characteristics of coatings was thoroughly investigated, as well as the solid particle erosion wear behavior of coatings. The results illustrated that the evenly dispersed TiO2 phase in AT13-1 coating was prone to homogenize the coating structure, resulting in better tribological characteristics than AT13-2 coating, although erosion wear performance was inferior to AT13-2 coating. The wear rate of AT13-1 coating was 1.36 × 10−5 mm3 (N m)−1, which was 1/21 times that of AT13-2 coating. At the 60° erosion angle, the high porosity of AT13-1 coating resulted in hard phase cracking or hard phase debonding. The high microhardness of AT13-2 coating reduced erosion wear at the 90° erosion angle.

Effect of carbide refinement on high temperature erosive wear behavior of high chromium white cast iron with different titanium and carbon additions

It is known that better erosion wear resistance of high chromium (27 wt% Cr) white cast iron (HWCI) with titanium (Ti) addition can be achieved by controlling the size of M7C3 carbides. Nevertheless, it might not be directly applicable to high temperature conditions due to the more complex factors involved, especially the hot oxidation behavior. Therefore, the effect of 0–2 wt% Ti and 3–4 wt% carbon (C) addition on the high temperature erosion wear behavior of HWCI has been investigated in this research. The results show that there are TiC and M7C3 carbides precipitated in the material matrix. The size of M7C3 carbides decreases drastically as the amount of Ti increases. On the contrary, it is effectively enlarged with the addition of higher C. In addition, there is no significant difference in hardness among all specimens due to the relatively similar carbide volume fraction (CVF). The wear resistance of HWCI is improved by increasing the amount of Ti although it has a lower value as the C content increases. It means that hardness is not an important factor in evaluating the wear characteristics of HWCI at high temperatures. The worn surfaces and cross-sections show that the smaller M7C3 carbides are more likely to undergo plastic deformation rather than being directly peeled out. In addition, the effect of hot oxidation behavior was negligible because there is only a very thin oxidation layer on the worn surface. Therefore, it can be concluded that the erosive wear behavior of the material is greatly influenced by the size of M7C3, which the material with better erosive wear resistance contains finer carbides.

Dry wear and corrosive wear behavior of laser-cladded Co19.6Cr19.6Fe19.6Ni19.6(B13.72Si5.88)19.6Y2 and Fe43.6Ni17.4Cr9Co6B17.5Si1.5Nb5 coatings

Corrosive wear is a key factor affecting the safe operation of offshore engineering equipment. In this study, Co19.6Cr19.6Fe19.6Ni19.6(B13.72Si5.88)19.6Y2 and Fe43.6Ni17.4Cr9Co6B17.5Si1.5Nb5 coatings were prepared on the surface of 304 stainless steel using laser cladding technology. Dry wear and corrosive wear behavior of both coatings and 304 stainless steel were comparatively studied under different loads. The results show that both coatings are mainly composed of FCC solid solution, boride, and Laves phases. The average microhardness of Co19.6Cr19.6Fe19.6Ni19.6(B13.72Si5.88)19.6Y2 and Fe43.6Ni17.4Cr9Co6B17.5Si1.5Nb5 coatings are 578.6 HV0.2 and 632.5 HV0.2, respectively. The dry wear resistance of Fe43.6Ni17.4Cr9Co6B17.5Si1.5Nb5 coating is approximately 3 times that of 304 stainless steel under all friction load conditions. It can be found that the Fe43.6Ni17.4Cr9Co6B17.5Si1.5Nb5 coating with high hardness is less sensitive to friction load changes during dry wear process. In 3.5 wt% NaCl solution, the corrosive wear resistance of CoCrFeNiBSiY coating under friction loads of 30 N and 50 N is 2.68 times and 2.83 times that of 304 stainless steel, respectively. The excellent corrosive wear resistance performance of the CoCrFeNiBSiY coating is mainly attributed to its superior corrosion resistance and repassivation ability. During the corrosive wear process, a dense passivation film is formed on the surface of both coatings, which significantly reduces their friction coefficient and volume loss rate.