Erosive Wear Properties Research Articles

Investigation of Friction and Erosion Wear Properties of Titanium and Titanium Alloy Pipes.

Titanium alloys are applied in oil and gas development and transportation to improve conditions because of their high specific strength and corrosion resistance. However, the disadvantage of poor wear resistance has become an obstacle to developing titanium alloys. The friction and wear properties of pure titanium TA3 and titanium alloy TA10 were tested under different loads and different friction forms using a reciprocating friction and wear tester. Moreover, the erosion resistance of pure titanium TA3 and titanium alloy TA10 was studied using a gas-solid erosion tester. The results show that the wear rate of TA3 and titanium alloy TA10 increases with increasing friction load. Under a load of 50 N, the mass losses of TA3 under dry friction and wet friction were 0.0013 g and 0.0045 g, respectively, while the mass losses of TA10 were 0.0033 g and 0.0046 g, respectively. While the load increased to 70 N, the mass loss of TA3 was even greater, reaching 0.0065 g, and the mass loss of TA10 was 0.0058 g. The wear forms of TA3 and TA10 include abrasive wear, adhesive wear and oxidation wear. The joint action of various friction forms leads to the loss of materials. Under the simulated working conditions, the erosion rates of TA3 and TA10 were 1.01 × 10-3 g/s and 0.94 × 10-3 g/s. The erosion mechanism is the same, including plowing, indentation and cracking.

A Tribological Study of CrN and TiBN Hard Coatings Deposited on Cobalt Alloys Employed in the Food Industry

In this work, a comparative study of the tribological performance of two hard coatings, CrN/TiBN, was conducted for research purposes and industrial applications in food products, particularly for food packaging into cans using the double hermetic sealing process. CrN and TiBN coatings were successfully deposited on a base-cobalt metal substrate of a CoCrW commercial alloy using physical vapor deposition by arc evaporation (AEPVD) technology to improve the tribological properties of the commercial alloy, including wear and corrosion resistance, lower coefficient of friction, and overall durability. This research focuses on conducting scratch and abrasion wear resistance tests in dry conditions; specifically, it pursues to evaluate the wear corrosion properties, known as tribocorrosion performance, on CrN/TiBN hard coatings. The experimental results show that the CrN coating (2.9 μm) is slightly thicker than the TiBN coating (2.7 μm), with a 47 N critical load. It also shows a lower coefficient of friction (CoF) in a dry environment, while the TiBN coating showed total detachment and a high coefficient of friction in a dry environment condition. Tribocorrosion testing in brine aqueous solution indicated that CrN coating shows a high friction coefficient with a higher open circuit potential value (Ecorr), and TiBN shows the lowest corrosion potential (Ecorr) and the lowest friction coefficient. This suggests that CrN could provide better corrosion protection for commercial cobalt alloys and improve tool performance during the food canning process in brine environments.

Investigation of the Corrosion–Wear Interaction Behavior of 8Cr4Mo4V Bearing Steel at Various Corrosion Intervals

The corrosion–wear coupling damage failure of 8Cr4Mo4V bearing steel under marine atmospheric conditions significantly limits aeroengine bearing applications. The present work aims to investigate the evolution of the corrosion–wear properties of 8Cr4Mo4V bearing steel at varied corrosion intervals and estimate the corrosion–wear interaction (CWI) effect. Neutral salt spray tests combined with tribological experiments were employed to explore the effect of corrosion on wear and the influence of wear on corrosion, and a quantitative characterization method of corrosion–wear interactions was proposed by establishing the component relationships of material losses in the corrosion–wear process. The results indicate that the corrosion rates initially increase and then decrease, ultimately resulting in a pattern characterized by predominant total corrosion and nested localized corrosion. The corroded surfaces tremendously influence the friction coefficient curves at the third stage, and a synergistic acceleration effect exists in the CWI behavior of 8Cr4Mo4V bearing steel under the action of corrosion and wear. A sample corroded for 6 h displayed the significant facilitative effect of corrosion on wear, exhibiting the highest CWI ratio and a greater total mass loss primarily attributed to corrosion. This study offers a significant reference for the quantitative assessment of the tribo-corrosion properties of bearings in a marine atmospheric environment.

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

Purpose This study aims to investigate the influences of Al2O3 mass fraction on the corrosive wear and electrochemical behaviors of FeAl–xAl2O3 coatings. Design/methodology/approach FeAl–xAl2O3 coatings were prepared on S355 steel by laser cladding to improve its corrosive wear and electrochemical properties. Findings The 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/value Al2O3 was first added into FeAl coatings to further improve its corrosive wear and electrochemical properties by laser cladding.

Effect of Polytetrafluoroethylene Coating on Corrosion Wear Properties of AZ31 Magnesium Alloy by Electrophoretic Deposition

In this study, we aim to enhance the corrosion and wear resistance of AZ31 magnesium alloy using electrophoretic deposition (EPD) technology to apply a hydrophobic polytetrafluoroethylene (PTFE) coating. Polyethyleneimine (PEI) serves as a charged dispersant, facilitating uniform deposition of PTFE particles on the alloy surface. Results demonstrate a significant reduction in corrosion current density (from 67.5 μA/cm2 to 5.2 μA/cm2) and improved wear resistance (wear volume decreased from 0.24167 mm3 to 0.00167 mm3) in a 3.5 wt% NaCl solution compared to uncoated alloy. Moreover, the friction coefficient of the coated sample decreases. These findings underscore the potential of nano-PTFE coatings prepared via EPD in enhancing AZ31 magnesium alloy’s corrosion and wear resistance, providing a foundation for future protective coating design and optimization.

The improvement of wear and corrosion resistance of nickel-graphite coating with modified graphite phase size

The corrosion resistance, friction and wear properties of an abradable seal coating are highly dependent on the size and distribution of lubrication phase. In this work, nickel-graphite (Ni-G) coatings were fabricated by a supersonic atmospheric plasma spraying system (SAPS) and a standard atmospheric plasma spraying system (APS), respectively. The effect of size and distribution of graphite phase on the performance of Ni-G coatings was investigated. The results suggested that the SAPS coating had an average single graphite phase area of 35.4 ± 5.1 μm2, which is approximately 35.4 % less than that of the APS coating, while the average graphite phase width and length in SAPS coating decreased by 22.2 % and 16.7 % compared to the APS coating. The fine distributed graphite phase improved the formation of structure with a small cathode and a large anode, which effectively increased the corrosion resistance of SAPS coating. The reciprocating sliding friction facilitated the creation of a uniform and uninterrupted lubricant layer, attributed to the finely dispersed graphite phase of SAPS coating. In comparison to the as-sprayed and subsequent corroded APS coatings, the friction coefficients of the SAPS coating exhibited a reduction of approximately 9.1 % and 13.3 %, respectively. The aforementioned findings showed that the small-sized graphite phase was conductive to the improvement of corrosion resistance, friction and wear properties of Ni-G abradable coatings.

Optimization of physico-mechanical and erosive wear properties of single/multilayer – coated granite filled aluminum alloy composites

Abstract In the present research, uncoated and coated (CrN/SiN–CrN) granite dust reinforced aluminum alloy (AA 1050, AA 5083) composites samples were fabricated using stir casting and their physical, mechanical and slurry erosion behavior were assessed. The study reveal a persistent increase in void content, hardness, impact strength and stress intensity factor for both uncoated and coated alloy with the inclusion of reinforcement. In contrast, flexural strength and corrosion rate decrease continuously with increased granite content and also with the corresponding coating. Multilayer coated 5083 aluminum alloy composite with 6 wt.% granite particle shows maximum hardness, impact strength and stress intensity factor and minimum slurry erosion rate. The entropy method was applied to the operating parameter to rank the fabricated composites. The performance of each operating parameter is determined using the VIKOR (Vise Kriterijumska Optimizacija Kompromisno Resenje) optimization method. The optimal formulation based on Performance-Defining Attributes (PDAs) is observed for multilayer-coated 6 wt.% granite particulate reinforced 5083 aluminum alloy composites.

Evaluation of mechanical and erosive wear properties of hybrid nano composites basalt/E-glass fiber + MWCNTs/SiO2

The extensive study conducted has revealed that the mechanical and other characteristics of hybrid composites are greatly influenced by several aspects, such as the kind of fibre reinforcement, nanofillers, matrix materials, and the manufacturing methods employed. In the context of structural applications, the incorporation of Multi-wall Carbon Nanotubes (MWCNTs) as fillers in E-Glass fibres had a significant impact on the rapid alteration of mechanical properties, particularly strength, in the composites. This study aimed to create hybrid nanocomposites by including multi-walled carbon nanotubes (MWCNTs) and silicon dioxide (SiO2) as filler materials, Basalt/E-glass as fibres, and epoxy with hardener as the matrix. This study utilises statistical methods, specifically the Taguchi L16 Orthogonal Array (OA), to analyse the impact of various operating factors. The parameters selected for this study include MWCNTs/SiO2 fillers at varying weight percentages (0 %, 1 %, 2.9 %, and 3 %), an epoxy matrix with decreasing weight percentages (40 %, 39 %, 38 %, and 37 %), compression pressures ranging from 5 MPa to 35 MPa, and moulding temperatures ranging from 40 °C to 100 °C. The mechanical parameters being examined are the tensile strength and erosive wear. The utilisation of the hand layup and compression moulding technique achieved the development of these composites. By optimising the moulding temperature, significant improvements were achieved in the tensile strength, which reached 184.38 MPa. Similarly, reducing the percentage of fillers resulted in a substantial decrease in erosive wear, with a value of 95.06 mg/kg.

Effect of TiO2 nanoparticles on the corrosion resistance, wear, and antibacterial properties of microarc oxidation coatings applied on AZ31 magnesium alloy

Microarc oxidation (MAO) is a surface modification process that is often adopted to produce a hard oxide layer on magnesium alloys to improve their corrosion resistance and wear resistance. However, under continual corrosion, the characteristic porous microstructure of MAO coatings provides diffusion paths that allow corrosive species to penetrate the coatings and react with the substrate underneath. Therefore, the present study investigated the modification of the microstructure of MAO coatings when adding TiO2 nanoparticles to a fluoride-containing silicate electrolyte system under the bipolar current mode. The results indicate that as the concentration of TiO2 nanoparticles increased, the quantity of rutile (TiO2) incorporated in the MAO coating increased, which led to the coating exhibiting an elevated hardness and a color change from white to gray-black. When the TiO2 concentration in the electrolyte was increased from 2.5 to 7.5 g/L, the total impedance of the MAO coating in electrochemical impedance spectroscopy analysis increased from 107 to >600 kΩcm2, which indicates that the corrosion resistance of the coating increased with the number of defects on it decreased. The addition of TiO2 enhances the photocatalytic properties of MAO coatings. However, excessive addition of TiO2 can lead to an adverse effect on the wear resistance of MAO coatings.

Concrete erosion mechanism and model research under the action of wind gravel flow in Gobi gale area

The surface covering of the Gobi gale area (GGA) primarily consists of medium-coarse sand and gravel, which can easily form a strong wind gravel flow (WGF) under the impact of high winds. Throughout the year, concrete bridge piers are exposed to WGF environments leading to severe erosion damage to their surface. This study investigates the influence of different gravel erosion parameters on concrete erosion wear (CEW) properties investigated through indoor erosion tests. It demonstrates that the concrete erosion rate (CER) initially increases and stabilizes over time. The higher the concrete strength class, the stronger its ability to resist erosion wear. The CER increased with the gravel attack angle and gravel flow. The erosion wind speed positively correlated with the CER, with a speed index between 2.13 and 2.96. When the gravel flow rate was the same, the mass loss of concrete primarily originated from the impact of small gravel. Although the size and depth of the erosion pits on the concrete surface are large under the impact of large-sized gravel, the mass loss is small. In addition, based on the bitter-deformation wear theory and the Oka erosion model, a concrete erosion model suitable for the WGF in Gobi was established. This study provides significant guidance for the protection and quality assurance of concrete structures in GGA.

Biomimetic composite structural water hydraulic valve plug for erosive wear resistance based on additive manufacturing processes

Developing materials with good erosive wear properties has broad prospects and economic benefits, especially in the field of water hydraulic system. By studying key information in the online biological strategy library-AskNature, we were able to identify strategies for improving the erosive wear resistance of materials. Specifically, we developed a biomimetic composite structural valve plug (BCSVP) with erosive wear resistance based on the multi-scale observation of shellfish, realized through additive manufacturing (AM). The phase composition and microstructure were analyzed by X-ray diffraction (XRD), scanning electron microscope (SEM), and energy dispersive spectrometer (EDS). The erosive wear resistance was evaluated by morphology observation and slurry erosive wear experiments. The results of these experiments indicate that the BCSVP exhibited a 26.3% higher volumetric erosive wear resistance than a 3D printed 316L stainless steel valve after 7 h of slurry erosive wear. This interdisciplinary research highlights the potential of BCSVP in applications requiring high slurry erosive wear resistance in water hydraulic applications.

Patients with gastroesophageal reflux disease (both reflux oesophagitis and non-erosive reflux disease): Prevalence and severity of erosive tooth wear and saliva properties.

The prevalence between erosive tooth wear (ETW) in association with reflux oesophagitis (RO) has been reported. However, the severity of both diseases and the relationship between ETW and non-erosive reflux disease (NERD) is unclear. The prevalence and severity of ETW were investigated in RO, NERD and healthy controls. 135 patients with RO, 65 with NERD and 40 healthy controls were recruited for this case-control study. A modified tooth wear index was used to evaluate the prevalence and severity of ETW. Salivary secretion and buffer capacity were assessed prior to endoscopy. The prevalence and severity of ETW, saliva properties among each group were analysed using Pearson's chi-squared test. A total of 135 cases (56.3%) were categorised as the patient with ETW (55 with mild RO, 49 with severe RO and 31 with NERD). There was a significant relationship between the prevalence of RO and ETW, while there was no significant correlation between the prevalence of NERD and ETW. There was a significant difference related to the severity between RO and ETW. For salivary secretion, there was a significant difference between with and without ETW in patients with mild RO, severe RO and NERD. There was a significant difference between with and without ETW for salivary buffer capacity in patients with mild and severe RO. There was a significant association of the prevalence and severity between RO and ETW. Clinical signs such as ETW and salivary buffer capacity depended on the severity of RO.

Study on the Effect of ELID Grinding on corrosion wear properties of Co-Cr Alloy

Contemporary Co-Cr alloys used in artificial joints can cause health complications in long-term applications. A pin-on-disc friction and wear testing instrument was used to evaluate the corrosion and abrasion of two types of Co-Cr alloys for artificial joints under simulated body fluid conditions after surface electrolytic composite grinding. Co-materials with lower carbon content displayed superior corrosion resistance than those materials with higher carbon content. Moreover, surface processing with electrolytic composite grinding produced a stable surface modification layer, which improved the surface hardness and formed an oxide film that inhibited metal ionization. The formation of precipitates in the corrosive environment is likely to improve the friction and wear properties of the material. As such, a variety of hardness was observed for the artificial joint friction disc and pin, especially when the hardness of the disc was higher than that of the pin, which can improve the friction and wear behavior of joints.

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.

Manufacturing of Corrosion-Resistant Surface Layers by Coating Non-Alloy Steels with a Polymer-Powder Slurry and Sintering.

This paper describes the combination of surface engineering and powder metallurgy to create a coating with improved corrosion resistance and wear properties. A new method has been developed to manufacture corrosion-resistant surface layers on steel substrate with additional carbide reinforcement by employing a polymer-powder slurry forming and sintering. The proposed technology is an innovative alternative to anti-corrosion coatings applied by galvanic, welding or thermal spraying techniques. Two different stainless-steel powders were used in the research. Austenitic 316 L and 430 L ferritic steel powders were selected for comparison. In addition, to improve resistance to abrasive wear, coatings containing an additional mixture of tetra carbides (WC, TaC, TiC, NbC) were applied. The study investigates the effects of using multicomponent polymeric binders, sintering temperature, and atmosphere in the sintering process, as well as the presence of reinforcing precipitation, microstructure and selected surface layer properties. Various techniques such as SEM, EDS, hardness and tensile tests and corrosion resistance analysis are employed to evaluate the characteristics of the developed materials. It has been proven that residual carbon content and nitrogen atmosphere cause the release of hard precipitations and thus affect the higher mechanical properties of the obtained coatings. The tensile test shows that both steels have higher strength after sintering in a nitrogen-rich atmosphere. Nitrogen contributes over 50% more to the tensile strength than an argon-containing atmosphere.

Investigation on the influence of laser peening on the erosion wear properties in TC21 titanium alloy

The study on improving the erosion wear resistance of TC21 titanium alloy through laser peening (LP) was carried out. The residual stress and full width half maximum (FWHM) in the gradient direction of the specimens before and after LP was analyzed, while the in-depth microhardness was also tested. The microstructural response generated by LP was observed using electron backscattered diffraction (EBSD). The erosion wear properties of differently processed specimens were finally trialed. The results indicated that LP effectively enhanced the erosion wear resistance of TC21 titanium alloy by generating grain refinement and compressive residual stress (CRS) without much deterioration of the surface roughness.

Mechanical and erosive wear performances of natural bamboo fibers/SiO2/epoxy ternary composites

Using natural bamboo fibers (BFs) and nano-SiO2 particles together can produce a certain synergistic effects, which may have a better toughening and strengthening effects than using any one of them separately. This study aims to investigate the effect of natural BFs and nano-SiO2 particles on the mechanical, physical characteristics and erosive wear performances of the BFs/SiO2/epoxy-based ternary composites. The samples were characterized using mechanical and physical testing, Fourier-transform infrared spectroscopy (FT-IR), scanning electron microscopy (SEM) and modified abrasive water jet device. The results showed that the fracture toughness and impact strength of polymer composites were significantly improved; this could be attributed to the excellent strengthening and toughening effects of the natural BFs and nano-silica particles. Additionally, the presence of the natural BFs and nano-SiO2 particles were found not only influence the toughness of the epoxy resin but also the absorptions of the kinetic energy of impact abrasive particles. It was observed that the maximum depth of the pit left on the composite was decreased when the BFs and SiO2 were added. As a result, the BFs/SiO2/epoxy-based ternary composites have improved mechanical and erosive wear properties, especially when the content of natural BFs is 15 wt% and modified nano-scale SiO2 is 3 wt%.

Enhancing corrosion and wear resistance of Mg coating on titanium implants by micro-arc oxidation and heat treatment

ABSTRACT Mg coating is one of the viable options for Ti to enhance its bioactivity. However, the rapid corrosion of Mg coating in physiological conditions has delayed their introduction for therapeutic applications to date. In this study, a ceramic layer between Ti substrate and Mg coating was prepared and heat treatment was also carried out to improve the corrosion resistance of the Mg coating. The in vitro test revealed that the ceramics layer decreased the galvanic corrosion between the Mg coatings and substrate, improved the corrosion resistance and wear properties. Furthermore, the post-heat treatment of Mg coating on Ti had a significant effect on the surface morphology and microstructure of the coating. The heat-treated Mg coatings on Ti at 400 °C for 10 min substrates showed an improved corrosion resistance compared with the untreated substrate. The heat treatment significantly influenced the hardness, adhesion, friction coefficient, and wear resistance of the coating.

Deposition of hard solid-lubricating composite coating on Ti-6Al-4V alloy with enhanced mechanical, corrosion, and electrical discharge wear properties

In the present work, a hard solid-lubricating clad layer has been developed on Ti-6Al-4V substrate by pre-placed powder TIG cladding technique to enhance the mechanical, corrosion and electrical discharge wear properties. The combining effect of Ti, Ni, and Si coating powders with different % of La2O3 in the N2 environment has been studied. The phase analysis detects peaks of both hard (NiTi, TiO2, and TiAlN) and solid lubricating (LaNi5 and Si3N4) phases. The sub-surface analysis shows defect-free cladding with good metallurgical bonds and refined microstructure near the interfacial zone. Mainly short and long dendrite, fish-bone-like, lamellar and short needle-like microstructures are observed. Two times higher microhardness in the range of 578.51 ± 13.99 HV0.5 (Sample S4) – 603.56 ± 9.66 HV0.5 (Sample S1) is observed. Mechanical wear analysis reveals a rigorous decrease in the coefficient of friction which is 14.5 times much better than titanium substrate. The prominent mechanism for mechanical wear is a combination of abrasion (Sample S1 and S2) with adhesion (Sample S3 and S4) with the lowest and highest wear rate of 63.92 ± 8.34 mm3 N−1 m−1 (Sample S4) and 154.52 ± 13.27 mm3 N−1 m−1 (Sample S1) respectively. The corrosion rate is found much lower than titanium substrate. The chance of the electrical discharge wear reduced to 81.90 % which is much better than titanium substrate. These results demonstrate that fabricated coating on Ti-6Al-4V substrate can be used in any of the mechanical, corrosion, and electrical discharge wear environments.

Effects of Zn, Nd, and Ca addition on the microstructure, mechanical and corrosion properties of biodegradable Mg-Ag alloys

In this study, casting, extrusion, biocorrosion and corrosive wear properties of 0.5 wt.% (Zn, Ca, and Nd) element added Mg-3%Ag alloys were investigated. As a result of the experimental studies, it was observed that the grains in the Zn and Ca added as-cast alloys became thinner, and thus the mechanical properties of the investigated alloys such as yield strength and hardness were improved. At the same time, the applied extrusion process provided an increase in the mechanical properties by refining the grain structure of the investigated alloys. As a result of in vitro tests, larger pitting was observed in as-cast alloys, while smaller and shallower corrosion pits were observed in extruded alloys. In the corrosive wear tests, the wear rate of extruded alloys generally showed a decreasing trend. However, the composition of both as-cast and extruded Mg-3% Ag-0.5%Zn-0.5% Ca was the alloy that exhibited the lowest value in terms of the wear rate.