Solid Particle Erosion Behavior Research Articles

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

Effect of solid lubricant additives on solid particle erosion characteristics of rigid and toughened epoxy resins

AbstractSolid lubricants are added to polymers to upgrade their tribological properties, especially in cases where adhesive and abrasive friction are valid. However, there are not enough studies on the effects of solid lubricants on particle erosion. This study investigated the effects on solid particle erosion behavior of three different well known solid lubricants (molybdenum disulfide, polytetrafluoroethylene, and graphite). These solid lubricants were added at three different ratios (5, 10, and 15 wt.%) to the two different type (rigid and toughened) epoxy resins. Garnet abrasive particles (180–400 μm) were blasted to the sample surface under 1.5 bar for 15 s to conduct solid particle erosion tests. The erosive wear mechanisms of neat and solid lubricant‐reinforced epoxy resins were investigated in relation to the epoxy type, solid lubricant type, and solid lubricant reinforcement ratio. Statistical analysis was performed according to response surface methodology to support the experimental results, and ANOVA tables were obtained. The wear and deformations that occurred on the surface after solid particle erosion were examined using a noncontact optical profilometer system and scanning electron microscopy, and a significant relationship was detected between the deformation on the surface and particle erosion. Analysis results showed that the factor causing the greatest erosion rate change was the epoxy resin type. Finally, it has been observed that all solid lubricants reduce the erosive wear resistance, and this resistance decreases as the weight ratio increases.Highlights Investigations were conducted into the erosion behavior of two types of epoxy resins: rigid and toughened. The toughened epoxy resin exhibited greater resistance to erosion. Although it has the same type of content, on average, rigid epoxy worn 2–4 times more than toughened epoxy. The effect of adding polytetrafluoroethylene tended to increase the erosion rate of both rigid and toughened epoxy resin less than that of other solid lubricants. Graphite particles increased the erosion rate of toughened epoxy by 1.5–3 times and that of rigid epoxy by 2–3 times, depending on the value of the reinforcement ratio. MoS2 increased the erosion rate of toughened epoxy by 1.5–3 times and that of rigid epoxy by 2–3 times. Using a noncontact optical profilometer (for investigating surface topography), it was proven that there is a significant relationship between the erosion rate and roughness characteristics. Wear mechanisms were identified by SEM analysis.

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

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

Optimization of solid particle erosion behavior of thermally sprayed nichrome on duplex stainless steel

Optimization of solid particle erosion behavior of thermally sprayed nichrome on duplex stainless steel

Investigation on Solid Particle Erosion Performance of Aluminum Alloy Materials for Leading-Edge Slat

This study aims to characterize solid particle erosion behaviors of three different aluminum alloys (AA2024-T351, AA6061-T651, and AA7075-T651) and reveal their erosion performances on leading-edge slat of airplane wings. Solid particle erosion tests were conducted using silicon carbide erodent particles under the conditions of six different impingement angles (20°-90°) and four different impact velocities (70-192 m/s). The erosion simulations of a leading-edge slat of the aforementioned aluminum alloys were numerically simulated at four different rotation angles (0°-15°) for three different impact velocities (130-250 m/s). A commercial ANSYS Fluent software using the Euler-Lagrange equation and an experimental data-based erosion model was used for the erosion simulations. The experimental results showed that the erosion rate increases with increasing impact velocity and the maximum erosion rate is obtained at the impingement angle of 30° which reflects the ductile manner. Of the three aluminum alloys, the AA6061-T651 exhibited the worst erosion behavior followed by the AA2024-T351 sample, whereas the AA7075-T651 had the best erosion resistance. The numerical results indicated that the erosion rate values of slat surfaces made up of three different aluminum alloys showed a slight increase after a slat rotation angle of 5°.

Solid particle erosion behavior of Graphene/SiC/Al2O3/TiO2 coated Kevlar/Epoxy composite materials

In light of the finding of a research-based solution for erosion with fabrication and test ceramic fillers incorporating composite material, this research used the electro-spun method to cover fibre mats with nanofiller materials such as graphene, SiC, Al2O3, and TiO2. This study delves into the erosive behaviour of recently created nanohybrid composite materials. The test consistently maintains the following parameters: impact velocity (60–80 m/sec), angle of impact (15° − 90°), standoff distance (ranging from 15 mm to 25 mm), and erodent size (ranging from 300 µm to 500 µm). The results demonstrated that as the impact velocity and erodent size rose, so did the erosion rate. The semi-ductile quality of the manufactured materials is shown by the highest erosion rate at a 60° impact angle. The smallest erosion rate is often seen at an impact angle of 15°, however. The graphene/Kevlar/Epoxy, graphene/SiC/Kevlar/Epoxy, graphene/Al2O3/Kevlar/Epoxy, graphene/TiO2/Kevlar/Epoxy, and Kevlar/Epoxy erosion rates range from 3.27 to 13.08, 6.39 to 14.71, 11.64 to 19.30, 13.52 to 23.35, and 22.19 to 51.61 mg/kg, respectively. In comparison to the erosion values reported for hybrid composite materials based on fillers, these numbers are quite low. When compared to a hybrid composite without nanoparticles, the overall weight reduction for graphene/Kevlar/Epoxy, graphene/SiC/Kevlar/Epoxy, graphene/Al2O3/Kevlar/Epoxy, and graphene/TiO2/Kevlar/Epoxy is 70.67 %-85.25 %, 59.23 %-75.38 %, 41.78 %-64.26 %, and 27.86 %-56.91 %, respectively. This research examines the process of morphological erosion. Examining degraded surfaces with a scanning electron microscope reveals microcracks, crack propagation, pushing action, ploughing action, displacement of fibres, and breaking.

Effect of Impact Angles and Temperatures on the Solid Particle Erosion Behavior of HVOF Sprayed WC-Co/NiCr/Mo and Cr3C2-CoNiCrAlY Coatings

Effect of Impact Angles and Temperatures on the Solid Particle Erosion Behavior of HVOF Sprayed WC-Co/NiCr/Mo and Cr3C2-CoNiCrAlY Coatings

Solid Particle Erosion and Scratch Wear Behavior of NiTi Smart Alloy Modified Mild Steel Using Atmospheric Plasma Spray Technology at Different Substrate Preheating Temperatures

Solid Particle Erosion and Scratch Wear Behavior of NiTi Smart Alloy Modified Mild Steel Using Atmospheric Plasma Spray Technology at Different Substrate Preheating Temperatures

Solid particle erosion and scratch behavior of novel scrap carbon fiber/glass fabric/polyamide 6.6 hybrid composites

AbstractThis study investigated the tribological performance of hybrid composites composed of scrap carbon fiber (CF), glass fabric (GF), and polyamide 6.6 (PA6.6) through an innovative approach for reusing scrap CFs in high‐value composite structures. The experimental setup included CF/GF/PA6.6 hybrid composite laminates with varying CF contents and surface‐modified GFs, as well as PA6.6 sheets and GF/PA6.6 composite laminates. Solid particle erosion and scratch tests were conducted to assess the influence of scrap CF hybridization and GF surface modification on the tribological properties of the composites. The results demonstrated that neat PA6.6 sheets exhibited the lowest erosion rate, while the incorporation of CF and GF reinforcements had a detrimental effect on erosion resistance. The highest erosion rate was observed within the impact angle range of 15°–30° for pure PA6.6 sheets, whereas for composite laminates, it occurred within the range of 30°–45°. In contrast, CFs positively affected scratch hardness despite their negative impact on erosion resistance. Additionally, the silane treatment of GFs, which enhanced interfacial strength, improved the erosion resistance and scratch hardness of GF/PA6.6 composite laminates without CF. Profilometer‐based topographic analysis revealed a correlation between the average surface roughness of the eroded surfaces and the weight loss resulting from solid particle erosion.

Study on solid particle erosion behavior of polymer functionally graded composites

Present research focussed on solid particle erosion behavior of epoxy/copper (Cu) functionally graded composites (FGCs). Four layered sample having different volume fraction (10%, 15%, 20%, 25%) of filler particles was developed using lay-up lamination and layered curing processes. Erosion behavior studied on abrasive-air jet testing apparatus using angular shaped silica sand erodent. Experiments were performed at impingement angles of 30°, 45°, 60°, 90° and impact velocity of 101 m/s, 119 m/s, 151 m/s and erosion rate was evaluated at different layers. Irrespective of impact velocity, FGCs showed greater erosion at 45° impingement angle which indicate their semi-ductile nature. At 45° and 101 m/s, wear rate at layer 4 comprising 25 vol% of Cu was 6.90%, 3.94%, and 1.77% lower than layer 1 (10 vol%), layer 2 (15 vol%), and layer 3 (20 vol%), respectively. Moreover, increment in erosion wear rate was observed to increase with an increase in impact velocity at all test parameters. Dominant wear mechanisms on eroded samples was observed using Scanning Electron Microscope (SEM).

Elevated temperatures erosion wear behavior of HVOF sprayed WC-Co-Cr/Mo coatings on Ti6Al4V substrate

The present research aims to investigate the effect of different impact angles and temperatures on volumetric erosion loss of WC-Co-Cr coating containing 10 wt% Mo. The composite coating was developed using High-Velocity Oxy Fuel (HVOF) process on a titanium substrate (Ti-31). A solid particle erosion behavior of the coatings is carried out at different impact angles (30°, 60°, and 90°) and temperatures (200 °C, 400 °C,600 °C, and 800 °C). The volumetric erosion loss of the coated samples was measured using an air jet erosion tester at high temperatures using Al2O3 as an erodent. The XRD, SEM/EDS, porosity, density, microhardness, bond strength, and scratch tests characterized the as-sprayed coatings. The 3D optical profilometer was employed to evaluate the volumetric erosion loss and the mode of erosion. The scratch resistance of WC-Co-Cr coating is better than WC-Co-Cr/Mo coating. The WC-Co-Cr coating shows a brittle mode of erosion up to 600 °C and a ductile mode of erosion at 800 °C. In contrast, the WC-Co-Cr/Mo coating shows a brittle mode of erosion at 200 °C and a mixed mode of erosion at 400 °C to 800 °C. The volumetric erosion loss of WC-Co-Cr is less than WC-Co-Cr/Mo for all temperatures and impact angles. The formation of oxide phases on the coating surfaces demonstrates erosion resistance at high temperatures. The results of volumetric erosion loss measured by the weight loss method correlate well with a non-contact type 3D optical profilometer.

Effect of In-process Cryogenic Cooling in the Burnishing Process on the Solid Particle Erosion Behavior of HVOF Cermet Coating

Effect of In-process Cryogenic Cooling in the Burnishing Process on the Solid Particle Erosion Behavior of HVOF Cermet Coating

The effect of matrix and interface properties modified by annealing on solid particle erosion behavior of carbon fiber reinforced polyetheretherketone

AbstractIn this study, various heat treatments (annealings) were applied to carbon fiber reinforced polyetheretherketone (CF/PEEK) samples at four different temperatures (185, 225, 265, and 305°C) along two different holding times (30 and 270 min). The effects of changing matrix morphology, degree of crystallinity, and fiber‐matrix interface properties on thermo‐mechanical properties were investigated by differential scanning calorimetry (DSC) and dynamic mechanical analysis analyzes. Also, annealed CF/PEEK samples were tested to determine solid particle erosion characteristics. It was observed that the matrix crystallinity, fiber/matrix interface properties, and tribological properties of the CF/PEEK composites changed significantly with the thermal history. There was an increase in the degree of crystallinity with the increase in annealing temperature. It was observed that the degree of crystallinity increased up to about 27% and the damping factor decreased up to about 45%. As a result of the solid particle erosion tests performed under normal impact conditions, it was determined that the formation of the transcrystalline layer formed by heat treatment adversely affected the solid particle erosion resistance of the CF/PEEK. Erosion resistance of the heat‐treated samples (having higher fiber/matrix interface) was approximately 50% lower compared to the quenched sample. While the erosion rate for quenched samples is 14.5 × 10−5 g/g, this rate rises to 26.1 × 10−5 g/g for annealed samples. In addition, surface topography was examined by means of an optical profilometry, and surface morphology was examined by means of scanning electron microscopy. These examinations confirmed the experimental results.

Investigation of Solid Particle Erosion (SPE) Behaviors of Thermal Barrier Coatings (TBCs) with YSZ Ceramic Top Coating

Gaz türbin motorları servis kullanım koşulları altında farklı birçok hasar mekanizmasına maruz kalmaktadır. Bunlardan birisi de yabancı madde hasarı (FOD) ve diğer yabancı partiküllerin (volkan küller vb.) oluşturduğu yüzey üzerinde meydana gelen hasar yapılarıdır. Bu durumlara bağlı olarak türbin bileşenlerini oluşturan türbin bıçağı ve kanatçık gibi komponentlerde dökülme ve pullanarak kalkma gibi hasar oluşumları meydana gelmektedir. Belirtilen partiküllerin yüksek hızlarda ve farklı açılarda malzeme yüzeyine tekrarlı çarpması sonucunda katı partikül erozyon (SPE) hasarları meydana gelmektedir. Bu çalışmada, Inconel 718 süper alaşım altlık malzeme üzerine CoNiCrAlY bağ ve yitriya ile stabilize edilmiş zirkonya (YSZ) içeriğine sahip seramik üst kaplamalar atmosferik plazma sprey (APS) püskürtme yöntemi kullanılarak üretilmiştir. Üretilen termal bariyer kaplama (TBC) sistemindeki SPE sonucu oluşan mikroyapısal ve yüzey üzerindeki oluşum gösteren değişimler incelenmiştir. SPE testleri alümina (Al2O3) partiküllerinin kullanılmasıyla literatürde yaygın olarak çalışılmayan 25°, 50° ve 75°’lik püskürtme açılarında çalışılmış ve bu açılarda yapılan erozif aşınma testlerinde ortaya çıkan hasar mekanizmaları ve erozif aşınma oranı ayrıntılı olarak incelenmiştir. TBC kaplamalı numunelerde en yüksek erozyon oranı 50°’lik çarpma açısında gerçekleşirken bu değeri sırasıyla 75° ve 25°’lik çarpma açısı takip etmiştir. Çalışmalarda gerçekleştirilen alansal pürüzlülük ölçümlerinde erozyon oranlarının alansal pürüzlülük değerleri ile doğru orantılı olduğu görülmüştür. En yüksek alansal pürüzlülük değerlerinin 50°’lik çarpma açısında oluşum gösterdiği görülmüştür.

Novel Thermal Barrier Coatings with Phase Composite Structures for Extreme Environment Applications: Concept, Process, Evaluation and Performance

In this paper, a novel concept in the field of phase composite ceramics has been proposed and applied for creating the topcoats of durable thermal barrier coatings (TBCs), which is one of the most critical technologies for advanced high-efficiency gas turbine engines in extreme environments. The phase composite ceramic TBCs were designed to demonstrate superior and comprehensive performance-related merits, benefits, and advantages over conventional single-phase TBCs with a topcoat of 8YSZ or Gd2Zr2O7, including thermal phase stability, thermal shock durability, low thermal conductivity, and solid particle erosion resistance. In this paper, we review and summarize the development work conducted so far related to the phase composite ceramic concept, coatings processing, and experimental investigation into TBC behaviors at elevated temperatures (typically, ≥1250 °C) using different evaluation and characterization methods, including isothermal sintering, a burner rig test, a solid particle-impinging erosion test, and a CMAS corrosion test. Two-phase (t’+c) zirconia-based TBCs demonstrated improved thermal shock and erosion resistance in comparison to conventional single-phase (t’), 8YSZ TBC, and Gd2Zr2O7 TBC, when used separately. Additionally, a triple-phase (t’+c+YAG) TBC sample demonstrated superior CMAS resistance. The TBC’s damage modes and failure mechanisms for thermal phase stability, thermal cycling resistance, solid particle erosion behavior, and CMAS infiltration are also characterized and discussed in detail, in terms of microstructural characterization and performance evaluation.

Evaluation of Solid Particle Erosion of EB-PVD TBCs under Thermal Cycling Conditions Based on a Stochastic Approach

The solid particle erosion behavior of electron-beam physical vapor deposition (EB-PVD) thermal barrier coatings (TBCs) was numerically evaluated under thermal cycling conditions. The erosion rates were calculated based on the mechanics-based formulae where the model parameters are fitted to the temperature-process-dependent test data available in the literature. A stochastic approach was applied to simulate the erosion behavior toward service conditions. The mechanics-based formulae were then validated by experimentally measured temperature and sintering-dependent erosion rates from the literature. The pseudoductile erosion behavior is identified for silica particles in the EB-PVD topcoat (TC) erosion system above the intermediate temperatures (~220 °C) due to the softening of partial molten silica particles, thus leading to an increase in the cutting wear and a decrease in deformation wear. The erosion rates are found to decrease versus temperature but increase versus thermal cycles. Such erosion behavior could be attributed to propagation of sintering cracks induced at elevated temperatures. The parametric calculations show that both erosion and thermal cycling parameters have a profound effect on the erosion mechanism of EB-PVD TC. The erosion rate increases at higher solid particle velocity and accumulated mass but displays a pseudoductile erosion behavior versus variation of impacting angles. Two types of erosion mechanisms were evaluated under different thermal cycling conditions. Under the burner cycling test with a short high-temperature dwell period, the erosion mechanism of EB-PVD TBCs is governed by temperature, while under an isothermal cycling test with a high-temperature long dwell period, the erosion is determined by sintering time. The failure mechanisms of EB-PVD TBCs under solid particle erosion processes are discussed combining internal cracking within topcoat and external erosion on the surface of topcoat.

Solid Particle Erosion Behavior on the Outer Surface of Basalt/Epoxy Composite Pipes Produced by the Filament Winding Technique

Basalt/epoxy composite pipes in a [±55]4 winding configuration were produced on CNC filament winding machines (10 N fiber tension and ~11 mm bandwidth). In the experiments, a 34 m/s impact velocity was set using the double-disc method, and five different particle impingement angles (30, 45, 60, 75, and 90°) were used to determine the erosive effect on the outer surfaces of filament wound composite pipes under the influence of 600 μm erodent particles with angular geometry in the test set, complying with the ASTM G76-95 standard. The winding patterns in the lamina (±55 angle-ply laminate region) and zigzag (±55 zigzag region) regions of BFR/EP pipes were determined to have significant effects on solid particle erosion resistance, as evidenced by the SEM images.

Erosion and wear analysis of fly ash filled GFRP composite

The present work involves the solid particle erosion behaviour and the dry sliding wear characteristics of glass fiber reinforced polymer (GFRP) matrix composite using fly ash as filler material is investigated. Five different composite samples (with 0, 5, 10, 15 and 20 wt.% of filler) are fabricated using the traditional hand lay-up method and characterized for their density and hardness properties. Subsequently, the erosion and wear behaviour of the presently prepared composite samples are investigated on air erosion tester and pin-on-disc tribometer, respectively. For the erosion test experiments are performed according to a full-factorial design of experiment (DOE) by considering the hardness of the composite and the impingement angle as the controllable parameters. For conducting the dry sliding wear test, the type of composite, load and speed are taken as input parameters and the experiment is carried out as per Box-Behnken DOE of Response Surface Methodology (RSM). The composite with 15 wt.% of filler depicted the highest hardness value. The wt.% of filler is found to have a significant effect on the erosion and wear behaviour with moderate filler (10 wt.%) providing the optimum result in both cases.

Investigation of solid particle erosion behavior of Fe-Cr alloy coating

Investigation of solid particle erosion behavior of Fe-Cr alloy coating

Solid particle erosion behavior of nichrome coated duplex stainless steel

Solid particle erosion behavior of nichrome coated duplex stainless steel