Erosion Wear Rate Research Articles

Modeling of Erosion in a Cyclone and a Novel Separator with Arc-Shaped Elements

Modeling of the separation of catalyst particles from gas using two devices, a cyclone and a novel separator with arc-shaped elements, was performed for fluidized-bed dehydrogenation of C4–C5 paraffins to isoolefins as an example. The proposed dust collector allows one to reduce erosive wear by several times (~6.5-fold) in identical regimes and at identical parameters of the process. The effect of particle size on erosive wear was analyzed under near-industrial conditions; the regions most susceptible to wear in the analyzed devices were identified, as well as the functions describing the dependence between the erosive wear rate and particle diameter for the cyclone and separator with arc-shaped elements, making it possible to predict wear in the devices were obtained.

Theoretical analysis of effect of technological processing conditions on corrosion wear rate of treated surface during operation of part, taking into account roughness and hardening degree of treated surface material

The results of the study of the influence of technological processing conditions on the rate of corrosion wear of the treated surface during operation, taking into account the roughness, as well as the degree and depth of the material of the surface layer of the part, due to the technological conditions of the cutting process, are presented.

Corrosion-erosion behavior and mechanism of Cu[sbnd]Mo co-doped CoCrFeNi high-entropy alloy coating prepared by directed energy deposition

Developing cost-effective and high-performance high-entropy alloy (HEA) coatings on demand is imperative. This study designed a class of HEAs on-demand by synergistic doping of Cu and Mo elements based on the first-principles and multi-principal alloy design concept. A CoCrFeNiCu0.25Mo0.75 HEA coating with outstanding corrosion and slurry erosion wear performances was fabricated on the duplex stainless steel using the directed energy deposition technique. The corrosion mechanism of the HEA coating in 3.5 % NaCl and 0.5 M H2SO4 solutions and the slurry erosion wear mechanism under a slurry concentration of 5 wt% were analyzed in combination with the density functional theory. The results indicate that the SQS crystal model is a better predictor of phases and properties of HEA than the VCA model. The HEA coating is a cellular structure that consists mainly of a face-centered cubic phase structure and contains a small amount of homogeneous sigma nanocrystalline secondary phase precipitation. Meanwhile, the passive film of the HEA coating is mainly composed of metal oxides and hydroxides. Cu is not oxidized during the corrosion process and always exists in the metallic form, which serves as a barrier layer to prevent the transfer of point defects. Mo with a larger atomic size can induce lattice distortion, enhance the coating strength and hardness, and reduce the density of point defects. Further, the slurry erosion wear rate of the HEA coating is lower at a 30° impingement angle than 90° for brittle erosion mode. At the 30° impingement angle, micro-cutting and ploughing are the main wear mechanisms of the HEA coating, while at the 90° impingement angle, micro-indents and craters are the main wear mechanisms. In addition, the corrosion and slurry erosion wear performances of CoCrFeNiCu0.25Mo0.75 HEA coating are better than the most reported once-formed HEAs.

Influence of the bath pH value on the microstructure and properties of a novel electrodeposited Ni-W-Ti3C2TX composite coating

According to the previous research, the hardness of Ni-W-Ti3C2TX composite coating is 24.3% higher than that of Ni-W alloy coating without adding Ti3C2TX. Meanwhile, the wear resistance and corrosion resistance of the composite coating are significantly better than that of Ni-W coating. It is known that the electrodeposition process parameters have a great influence on the performance. The Ni-W-Ti3C2TX composite coating was prepared by the direct current deposition method. The influence of bath pH on the morphology, composition, mechanical properties, corrosion resistance and friction resistance of the coating was systematically studied. The results show that the surface morphology of the coating is improved with the increase of pH value. The content of W in the coating decreases from 44.95 wt.% to 12.66 wt.%, and the grain size decreases from 77.1 nm to 8.9 nm. The hardness of the coating increases first and then decreases with the increase of pH under the joint action of fine grain strengthening and solution strengthening. When pH is 9, the corrosion resistance and tribological properties are the best, and the corrosion current density and wear rate are 1.782 × 10−3 mA·cm−2 and 0.865 × 10−6 mm3·n−1·m−1, respectively. A suitable pH value provides excellent surface quality, appropriate grain size and good hardness for the composite coating to show excellent corrosion resistance and friction resistance.

Role of multiple mid-temperature tempering on mechanical properties and wear behavior of carburized steel under complex service conditions

Tempering is a necessary heat treatment process to ensure that the surface of the carburized material has adequate strength and the core has sufficient toughness. In this work, the carburized layer was tempered several times at medium temperature (400–440 °C) and the effect of tempering temperature, and number of times on microstructure, plastic toughness, and wear properties in complex environments was investigated in detail. The modified layers of the tempered samples were characterized by martensite, carbide, and a small amount of residual austenite. Primarily, the results show that the maximum ultimate tensile strength (UST, 1441 MPa) and elongation (11.4 %) were obtained with 3 times tempering at 400 °C. Simultaneously, the least erosion wear rate (0.61 mg/g) was obtained for 400 °C 3-times tempered specimens. Then, under dry friction conditions, the friction coefficients of the 3-times tempered were inferior to those of the 5-times tempered samples. In the subsurface layer, the 420 °C 3-times tempered samples had the minimum wear rate (1.73 × 10−15 m3N−1 m−1). Nevertheless, the friction coefficient under oil lubrication is dramatically lower compared to the dry friction coefficient. Finally, the medium temperature multiple tempering ensured a well-balance of wear resistance and plastic toughness.

Effect of duty cycle variation on Nickel electrodeposits at 10 Hz frequency

In this paper, nano nickel coating was made by pulsed electrodeposition technique to improve the surface properties of base metal. The developed nickel coating was characterized using SEM, Xrd, Vickers microhardness, Potentiodynamic polarization and ball on plate wear testing. X-ray diffraction studies shown that predominant (111) crystalline plane and finer grain size were obtained with lower duty cycle at 10 Hz frequency of pulse current. Pitting corrosion resistance of coated samples was evaluated at 3.5 wt. % of sodium chloride solution. An improvement of corrosion protection efficiency and good mechanical properties were achieved at lower duty cycle. As the duty cycle decreases, the corrosion current and wear rate decrease, and the micro hardness value increases. The average grin size was observed to be 75 nm and the newly developed nickel coated surface shown strong metallurgical bonding with the low carbon steel substrate material.

Erosion Behaviors of Gas–Solid Flow on an Assignment Plate using CFD–DEM

The erosion wear of a gas–solid flow is a major challenge for an S Zorb reactor; it affects the production safety and stability. This study aims to investigate the erosion wear problem of a gas–solid flow on an assignment plate in an S Zorb reactor using CFD–DEM. The erosion wear behavior of the assignment plate is studied through flow field and particle trajectory analyses. Moreover, five polyhedral particle models were established by DEM to study the effect of particle shape on erosion behavior. The numerical calculation results show that the special structure of the bubble cap affords a special serrated erosion wear area. According to the movement process of particles, the erosion wear of the assignment plate is divided into two stages: first a large range of slight erosion wear occurs and then seriously concentrated erosion wear occurs. With the decrease of particle sphericity φ, the erosion wear rate first decreases rapidly and then increases slowly. φ=0.85 is the critical value of change, and the assignment plate has the lowest erosion wear rate. The simulation studies are helpful for reducing the erosion wear of the assignment plate and improving its service life.

Performance Prediction of Erosive Wear of Steel for Two-Phase Flow in an Inverse U-Bend

Erosion of the elbow due to non-Newtonian viscous slurry flows is often observed in hydrocarbon transportation pipelines. This paper intends to study the erosion behavior of double offset U-bends and 180° U-bends for two-phase (liquid-sand) flow. A numerical simulation was conducted using the Discrete Phase Model (DPM) on carbon steel pipe bends with a 40 mm diameter and an R/D ratio of 1.5. The validity of the erosion model has been established by comparing it with the results quantified in the literature by experiment. While the maximum erosive wear rates of all evaluated cases were found to be quite different, the maximum erosion locations have been identified between 150° and 180° downstream at the outer curvature. It was seen that with the increase in disperse phase diameter, the erosive wear rate and impact area increased. Moreover, with the change of configuration from a 180° U-bend to a double offset U-bend, the influence of turbulence on the transit of the disperse phase decreases as the flow approaches downstream and results in less erosive wear in a double offset U-bend. Furthermore, the simulation results manifest that the erosive wear increases with an increase in flow velocity, and the erosion rate of the double offset U-bend was nearly 8.58 times less than the 180° U-bend for a carrier fluid velocity of 2 m/s and 1.82 times less for 4 m/s carrier fluid velocity. The erosion rate of the double offset U-bend was reduced by 120% compared to the 180° U-bend for 6 m/s in liquid-solid flow.

Curing kinetics, thermal and erosive wear characteristics of bismaleimide blends modified by polyaryletherketone

The work aimed to study the effect of thermoplastic polyaryletherketone (PAEK) on the curing kinetics, thermal stability and erosive wear performances of bismaleimide (BMI) resin blends. Toughened bismaleimide blends were fabricated using the allyl compound modified bismaleimide resin prepolymer as matrix and PAEK as a toughening agent by blending method. The modified PAEK/BMI blends were characterized and analyzed using the fourier transform infrared (FTIR), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), the swirling water jet erosive wear apparatus, scanning electron microscope (SEM) and three-dimensional surface profilometer. No obvious glass transition was observed for PAEK modified BMI blends in the temperature range of 50–350°C. In addition, the char yields ( Yc) and the heat-resistance index ( THRI) of the PAEK/BMI blends were affected by PAEK addition. The kinetic parameters, such as the activation energy and the pre-exponential factor of the PAEK/BMI blends were also higher than that of unmodified BMI blends, indicating that the incorporation of PAEK could promote the curing reaction of the epoxy resin without changing the curing mechanism. The erosive wear rate increased with the addition of PAEK especially when the mass fraction of PAEK was 10 parts per hundred of resins ( phr.). These results suggested that the thermal stability of the PAEK/BMI blends was significantly enhanced while the erosive wear resistance decreased by introducing the PAEK.

CFD Simulation and Experimental Results Validation of Slurry Erosion Wear using Slurry Pot Test Rig

Erosion wear is a severe issue in different industrial applications results in economic costs and operational failure. In most of the industry pipelines are used to handle the slurry during industrial process, the slurry handling pipeline is failure due to erosion wear. The slurry pot test rig is developed and fabricated for investigating the erosion wear rate of different material and solid particles used in the slurry pipeline with various working conditions. The various influencing parameters such as solid particle flow velocity, impact angle, solid particle size, and concentration are responsible for the rate of material loss and erosion wear mechanisms. The present study is based on experimental work and its validation of results of slurry erosion wear for slurry handling pipeline using slurry pot test rig and CFD simulation. For experimentation, mild steel is used as pipeline material and coal bottom ash is used as solid particles for simulating slurry handling pipeline use in a thermal power plant. The experimentation is performed on the slurry pot test rig. The computational fluid dynamics (CFD) tool is used to predict and simulate the experimental results of the slurry pot test rig. The simulation results compared with experimental results and check the percentage of errors with both the results. The simulation results show a similar kind of trend for erosion wear behavior of mild steel as per the experimental results. Simulation results show the average error up to ± 21% variation with the experimental result. The simulation results give the position of erosion wear over the sample surface.
 HIGHLIGHTS
 
 Erosion wear is the major problem in slurry handling industries (thermal power plant, chemical industries, hyro-power plants, coal minis) and components (Pipelines, Centrifugal pumps, flow control valve, turbines etc.)
 Experimental worked conducted to find the erosion wear rate and material removal mechanism of pipeline material (MS) with simulating thermal power plant conditions. Similarly software simulation analysis performed for same conditions
 The experimental results give the exact value of erosion wear rate but it does not show the position of maximum wear over the sample surface. Therefore, the experimental results are used for finding the erosion wear rate i.e. value of the sample and simulation results are used for finding the position of maximum erosion wear over the target sample
 
 GRAPHICAL ABSTRACT

Erosion wear characteristics of step-wise layered polymer composite materials by silica sand particles

Polymer composite materials (PCMs) can sustain themselves in harsh environments without suffering any loss of properties of the constituents. The present study focussed on erosion wear behavior of step-wise layered polymer composite materials (LPCMs). Samples were fabricated with epoxy as matrix and aluminum as filler particles using hand lay-up technique. Volume fraction of the filler was varied at four different layers along the direction thickness. Experiments were conducted at room temperature using angular shaped silica sand erodent impacting at 151 m/s and at impingement angles of 30°, 45°, 60° and 90°. Due to the variation in filler content, testing of samples was performed at two different orientations: i) top to bottom (T-B) and ii) bottom to top (B-T). The increased filler content reduced the erosion wear as tested from B-T, while a reverse trend was observed along T-B. Moreover, erosion wear was found to be higher at 45° impingement angle indicating the semi-ductile nature of LPCMs. At this angle, the erosion wear rate at top layer was 76.47% lower compared to bottom due to the presence of high filler content.

Solid particle erosion, water absorption and thickness swelling behavior of intra ply Kevlar/PALF fiber epoxy hybrid composites

AbstractIn this investigation, the different weaving pattern of intra ply Kevlar and pineapple leaf fiber (PALF) reinforced with epoxy hybrid composites was fabricated using the compression molding method. Solid particle erosion wear properties, water absorption, and thickness swelling behavior were tested. Solid particle erosion wear properties were tested using an air‐jet erosion tester. The various factors for solid particle erosion test were taken as impingement angle, exposure time, and weaving pattern. The weaving pattern was varied as plain type, twill type, basket type. The result showed that basket weave type and pure Kevlar fiber reinforced epoxy composites have better water absorption and thickness swelling properties. The results from the solid particle erosion test indicated that twill type and pure Kevlar fiber reinforced epoxy composites showed superior erosion wear resistance compared to other composites. Further, the statistical analysis was carried out using Taguchi analysis and their results showed that twill type Kevlar/PALF reinforced with epoxy composite was a minimum erosion wear rate at 90° of impingement angle and 6 min exposure time. The erosion mechanism of the surface eroded composite specimens was investigated using scanning electron microscopy.

Neural Network Prediction of Slurry Erosion Wear of Ni-WC Coated Stainless Steel 420

In the present study, Erosion wear of stainless steel 420 was predicted using an artificial neural network (ANN). Stainless steel 420 is used for making slurry transportation components, such as pump impellers and casings. The erosion wear performance was analyzed by using a slurry pot tester at the rotational speed of 600–1500 rpm with a time duration of 80–200 min. Fly ash was used as an erodent medium, and the solid concentration varied from 20 to 50%. The particle size of erodent selected for the erosion tests was <53 µm, 53–106 µm, 106–150 µm, 150–250 µm. A standard artificial neural network (ANN) for the prediction of erosion wear was designed using the MATLAB program. Erosion wear results obtained from experiments showed a good agreement with the ANN results. This technique helps in saving time and resources for a large number of experimental trials and successfully predicts the erosion wear rate of the coatings both within and beyond the experimental domain.

Erosive wear analysis of bamboo fiber‐reinforced high‐density polyethylene composites: Effect of aluminum oxide

AbstractIn order to improve the erosive wear resistance of bamboo fiber‐reinforced high‐density polyethylene (HDPE) composites, the effect of aluminum oxide (Al2O3) on the erosive wear behavior of composites was investigated. The study of erosive wear was using the swirling water jet technique. The results showed that the addition of nanoscale Al2O3 could optimize the structural strength, composite structure, and erosive wear resistance of composites. The best erosive wear resistance was observed in composites containing 6/189 wt% of nanoscale Al2O3, 80/189 wt% of bamboo fiber, 100/189 wt% of HDPE, and 3/189 wt% of maleic anhydride grafted polyethylene. The composites with and without adding nanoscale Al2O3, both exhibited a maximum erosive wear rate at a shooting distance of 0.5 cm and an erosive duration of 180 s. The erosive wear mechanism of composites mainly included pulverization of bamboo fibers, brittle fracture of HDPE matrix, and increasing in oxygen content.

CFD modeling of slurry flow erosion wear rate through mitre pipe bend

Erosive wear caused by particulates slurry is one of the major concerns in the pipe bend which may results in the failure of the pipe flow system. In the present work, erosion wear rate through mitre pipe bend caused by silica sand particulates slurry has been investigated using ANSYS Fluent code. The solid spherical particulates of size 125 µm and 250 µm having density of 2650 Kg/m3, were tracked to compute the erosion wear rate using Discrete Phase Method (DPM) model. The particulates were tracked using Eulerian-Lagrange approach along with k-ɛ turbulent model for continuous fluid phase. The silica particulates were injected at solid concentration of 5% and 10% (by weight) from the pipe inlet surface for wide range of velocities viz. 1–8 ms−1. The erosion wear rate was computed through four computational erosion models viz. Generic, Oka, Finnie and Mclaury. Furthermore, the outcomes obtained through Generic models are verified through existing experimental data in the literture. Moreover, the results of DPM concentration, turbulence intensity and particle tracking were predicted to analyze the secondary flow behaviour through the bend cross section. Finally, the effect of particulate size, solid concentration and flow velocity were discussed on erosion wear rate through bend cross section. The findings show that the locality of maximum erosive wear is positioned at the extrados of the bend outlet cross section. Additionally, it is found that Mclaury model offers higher erosion rate as compared to the other models and provides benchmark for designing the slurry pipeline system.

Erosive wear characteristic of Mo-TiN composite coatings on turbocharger compressor wheel using Taguchi experimental design

In the present work, Mo coating (S1) and Mo–TiN coatings with varied compositions (S2: Mo–5 wt% TiN, S3: Mo–10 wt% TiN, and S4: Mo–15 wt% TiN) were deposited using atmospheric plasma spray system on to Al-Si substrate. The solid particle erosion wear response of these coatings was studied following Taguchi experimental design. The signal-to-noise ratio was analyzed to investigate the influence of operating parameters (torch input power, erodent size, impact velocity, erodent temperature, impingement angle) on the erosion wear rate. In the case of Mo-coatings, erodent size is found to be the most influencing parameter. However, with incorporation of TiN powder to the molybdenum matrix, torch input power level is playing a significant role. Erosion rate is found to be decreased with increasing torch input power in the range of 15–30 kW in Mo-TiN coatings. In Mo–10 wt% TiN coating (S3), the least erosion rate is observed at 30 kW. The surface morphology of the eroded coatings shows less micro-cracks in S3 coating compared to others.

Erosion behavior of Tungsten carbide-cobalt and alumina coatings on stainless steel 316

Erosion may be defined as the destruction of a material by abrasive action of a liquid or gas. The wearing away is purely mechanical with no electro-chemical reaction. This process occurs on surfaces, pipelines wherever the flow of liquid along with particles in suspension causes erosion. In this investigation, the erosion rate on a coated surface was studied using pot erosion tester. The substrate material used was stainless steel of grade 316. The material was machined to the required dimensions and was coated one set with tungsten carbide- cobalt and another set with alumina. The coating was done using a detonation spray process. The specimens were weighed before and after the testing. The mass loss and erosion wear rate were calculated. It was found that the erosion wear rate was minimum when the speed of rotation was 3 m/ sec and increases as the speed increases. The SEM examination revealed the formation of flake type debris due to the interaction between the erodent and the specimen.

Microstructure, mechanical and erosion wear analysis of post heat treated iron alloy based coating with varying chromium

AbstractThe present work focuses on the effect of annealing heat treatment on the microstructure, mechanical and erosion properties of iron alloy based coatings with varying chromium content. High velocity oxygen fuel coating method was used to deposit the coating over the substrate material 316 L stainless steel. The study was done in terms of microstructural analysis using x‐ray diffractometer, surface and cross‐sectional morphology using field emission scanning electron microscope, mechanical and erosion wear analysis. It was found that x‐ray diffractometer indicated presence of less amount of titanium dioxide (TiO2) and silicon dioxide (SiO2) after heat treatment. However, the peaks of hardened phase of diironylidenetitanium (Fe2Ti) and iron‐chromium (Fe−Cr) was increased. Addition of chromium up to 10 wt. % improved the hardness and adhesion pull of strength by 16 % and 62 % respectively. On the other side heat treatment of iron alloy based coating having 10 wt. % chromium increased the hardness and adhesion pull off strength by 17.3 % and 35 % respectively. The erosion wear rate was also decreased with the annealing process. The study shows that the annealing process increases hardness and adhesion pull off strength but decreases porosity and erosion wear rate.

Significance of plasma electrolytic oxidation treatment on corrosion and sliding wear performances of selective laser melted AlSi10Mg alloy

In this investigation, Plasma Electrolytic Oxidation (PEO) process was used to prepare an alumina (Al 2 O 3 ) coating for corrosion and wear protection of a Selective Laser Melted (SLM) AlSi10Mg alloy radiator. The phase compositions, microstructures, mechanical properties, corrosion properties and wear resistance of the SLM AlSi10Mg alloy and the PEO coatings were investigated systematically. It was observed that the AlSi10Mg alloy prepared by SLM displayed a denser microstructure, finer grains and excellent mechanical properties with an average ultimate tensile strength of 402 MPa and an elongation of 9.9%. In addition, a double-layered coating with Al 2 O 3 as the top layer having a thickness of ~20 μm and a hardness of 1051HV 0.01 was realizable on the SLM AlSi10Mg alloy by PEO treatment. The corrosion current density and wear rate of the PEO Al 2 O 3 coatings were 5.7 and 279.3 times lower compared to the plain SLM AlSi10Mg alloy. The results indicate that the PEO treatment can significantly improve the wear and corrosion resistance of the AlSi10Mg alloy prepared by the SLM process. • AlSi10Mg alloy prepared by SLM exhibits dense microstructure and fine grain size. • AlSi10Mg alloy prepared by SLM process has excellent mechanical properties. • PEO film has dense outer layer and less dense inner one whose main phase is γ-Al 2 O 3. • PEO can provide excellent corrosion and wear protection for the SLM AlSi10Mg parts.

Wear performance analysis and characterization of HVOF deposited Ni–20Cr2O3, Ni–30Al2O3, and Al2O3–13TiO2 coatings

The present study was aimed to analyze a slurry erosion failure of SS316L steel coated with high-velocity oxygen-fuel coatings using Ni–20Cr2O3, Ni–30Al2O3, and Al2O3–13TiO2. Slurry erosion experiments were performed using a pot erosion tester for the time duration of 90–180 min at different velocities. The sand particles were used as an erodent to study the erosion wear phenomenon. The concentration of the two-phase slurry was kept in the range of 30–60 wt%. It was seen from the results that speed of rotation, concentration (wt%), and time duration play a vital role in the erosion wear rate of the coated and uncoated AISI 316L. Except for the impingement angle, an increase in the value of all parameters increases the deterioration of parent material with and without coatings. The deterioration rate of the parent material was improved by using coatings. Erosion performance of the AISI 316L was improved by an average of 43.06%, 23.55%, and 13.73% respectively with the deposition of Ni–20Cr2O3, Ni–30Al2O3, and Al2O3–13TiO2 HVOF coatings while all the parameters were varied from lowest to the highest value. Microscopically, the microcutting, smear regions, debonding, lip formation, fracturing, and cracks wear mechanisms occur in Ni–20Cr2O3 HVOF coating. The Ni–30Al2O3 HVOF coating underwent debonding, crater, microcutting, fracturing, ploughing, and lip formation. The major wear mechanisms in Al2O3–13TiO2 coatings are identified as smear, crater, pitting, microcutting, debonding, fracturing, cracks, ploughing, and lip formation.