Solid Particle Erosion Behavior Research Articles

Influence of particle attrition on erosive wear of bends in dilute phase pneumatic conveying

Bulk materials like sand particle/alumina, which do not possess good air retention properties or high permeability are generally conveyed in the dilute phase, suspension flow in conventional pneumatic conveying systems. High inlet conveying air velocity is thus necessary to successfully convey such materials. As a result of high air velocity, the particles impact on the bend surface and cause erosion of bends and attrition of particles. The study of bend erosion has been a subject of research for a long time and the influence of various operating parameters has been widely investigated. The authors have carried out an extensive experimental plan to study the influence of recirculation of material on the erosion of bends and attrition of particles. It is expected that the severity of erosion may go down as the particles lose sharp edges due to the recirculation of material. Silica sand having a mean particle size of 435 μm was conveyed in the pneumatic conveying pilot plant. The pipeline test loop is 48 m long and 67 mm bore. The bends were placed in horizontal-horizontal orientation with R/d ratio of 4.0. The solid particle erosion behavior of three test bends (B1, B2 and B3) and particle attrition have been analyzed. A 300 kg batch of sand was recirculated 29 times through the test pipeline, thus conveying a total of 8.7 tonnes. The mass loss and bend wall thickness were regularly monitored. Material sample during each run was collected to assess the extent of particle attrition and changes in the particle morphology.This paper presents the experimental results of a comprehensive analysis of the erosion and particle degradation with a change in particle morphology. A correlation has been developed between the extent of material recirculated through the test pipeline and its influence on the erosion of bends and degradation of particles.

Improvement of solid particle erosion resistance of helicopter rotor blade with hybrid composite shield

In the present study, the solid particle erosion behavior of polyurethane (PU) tape (3M-8663) material, bidirectional carbon fiber reinforced epoxy (CF/EP) and glass fiber reinforced epoxy (GF/EP) composites has been characterized experimentally and numerically. In the experimental part, steady-state erosion rates of aforementioned materials have been evaluated at different impact angles (20°, 30°, 45°, 60°, and 90°) and different impact velocities (70, 110, 150, and 190 m/s), and compared with those of stainless steel (SS304) and pure nickel materials (Ni) which are commonly used for erosion shield of helicopter rotor blades. Tests were conducted at room temperature using silica (SiC) particles (average diameter of 175 µm) as an erodent. Erosion behaviors on the shield surface of the same materials were investigated numerically under different impact velocities (110, 150, 190, and 230 m/s) for a pitch angle of 0°. Numerical erosion simulations were realized with commercial ANSYS-Fluent software using the finite volume method, an erosion model, and a discrete phase method with the Eulerian-Lagrangian approach. The experimental results showed that the GF/EP and the CF/EP composites indicated the maximum erosion rate at the impact angles ranged from 60° to 90°, whereas the PU tape material exhibited the maximum erosion rate at the impact angle of 30°. The results also showed that the PU tape surface clearly provided much better erosion resistance than the GF/EP and CF/EP composite surfaces, and the hybrid erosion shield having the PU/SS304 surface significantly improved the erosion resistance of the helicopter rotor blade up to the impact velocity of 150 m/s. A good agreement was also observed between the experimental and the numerical results.

SOLID PARTICLE EROSIVE WEAR BEHAVIOR OF Sol–Gel-DERIVED AA2024 THERMAL BARRIER COATINGS

Solid particle erosion behavior of non-conventional thermal barrier coatings prepared by dip coating of sol–gel 7[Formula: see text]wt.% yttria-stabilized zirconia (7YSZ) has been studied in the present paper. The purpose was to show its applicability to protect aeronautic bodies vulnerable under solid particle impact, e.g. the leading edges of the wings, the radome or the leading edges of rotor blades. The effect of operational variables on erosion rate is studied both for uncoated AA2024-T351 substrate and sol–gel-derived 7YSZ top-coat on AA2024-T351 substrate. The interactive influence of variables on erosive wear behavior is also systematically studied using an air-jet erosion tester under four different parameters such as temperature (25, 150, 275 and [Formula: see text]C), impact angle ([Formula: see text], [Formula: see text], [Formula: see text] and [Formula: see text]), impact particle velocity (40, 60, 80 and 100[Formula: see text]m/s) and erodent flow rate (2, 3, 4 and 5[Formula: see text]g/min) using L[Formula: see text] Taguchi design of experiments. The optimal experimental parameters were obtained by orthogonal arrays, signal-to-noise ratio (SNR) and analysis of variance (ANOVA) for uncoated and coated aluminum alloys AA2024-T351. The temperature was found to be the most influencing parameter followed by impact angle, impact velocity and erodent flow rate for uncoated samples. For 7YSZ sol–gel coated samples, temperature was the most influencing parameter followed by impact angle, erodent flow rate and impact velocity.

High temperature solid particle erosion behaviour of SS 316L and thermal sprayed WC-Cr3C2–Ni coatings

The boiler tubes, steam and gas turbines are commonly affected by severe high-temperature erosion wear due to impingement of solid particles entrained in the stream of fluid. The investigation focuses on the applicability of thermal sprayed WC based coatings for turbines and boiler tubes by improving the erosion resistance of the base material. The present work includes high-temperature solid particle erosion behaviour of WC-Cr3C2–Ni coatings deposited by atmospheric plasma spray (APS) and high-velocity oxy-fuel (HVOF) processes. The effects of temperature and impact angle on erosion performance of uncoated and coated specimens were comparatively studied using air-jet erosion tester (ASTM G76). The eroded surface morphology was analysed using a scanning electron microscope (SEM). Uncoated steel exhibit ductile mechanisms; however, both coated specimens follow the mixed mode of material removal under the same operating conditions. Erosion resistance of APS and HVOF coatings is approximately two and three times higher than uncoated specimens at higher temperatures under 30° and 90° impact angles. The HVOF coating offers higher erosion resistance than APS coating due to lower porosity, greater splat adhesion, a lower degree of decarburisation and higher inter-splat sintering at elevated temperatures.

Study of solid particle erosion behavior of HVOF spray coated superco-605 superalloy

Erosion is considered to be a key factor which has a significant role in many engineering setups like turbines, chemical processing equipments and aero engines, power generation units, etc. this investigation evaluates the property of erosion resistance of HVOF spray coated (Al 2 o3 + NiCrBSi) Superco-605 super alloy, the erodent feed rate maintained was 5gm/min, the angle of impact was 30°, 60°, and 90°, used erodent material is silica sand which has particle size of 150 µm. Erosion rate is determined as the ratio of weight loss of the material to the weight of the erodent, and also steady state volumetric rate of erosion is determined as the ratio mean of rate of erosion to the material density, investigations of the plots reveal that erosion rate of HVOF spray coated SuperCo-605 superalloy is higher at 90° angle of impingement and it tends to be lesser at 30°angle of impact, and in the same way for uncoated Superco-605 also, as for as steady state volumetric erosion rate is concerned it is also showing the similar response as that of erosion rate.

Influence of temperature, impact angle and h-BN content on the erosive wear behavior of hot-pressed SiC-BN composites

Owing to the unique combination of high strength, high hardness, and excellent thermal shock resistance, SiC-BN composites can be a potential candidate for components of exhaust systems where material loss by erosion is a major concern. In view of the foregoing, the present investigation deals with the solid particle erosion behavior of hot-pressed SiC composites with varying h-BN content: 0, 4, and 10 vol%. Erosion tests were conducted using SiC particles (size of 50–70 μm) at different impingement angles: 30°, 60°, and 90° and temperature: room temperature (25 °C) and high temperature (800 °C). The dominant erosive wear mechanisms were determined using SEM-EDS, XRD, Raman spectroscopy and XPS analyses. Results indicated that the erosion rate of the investigated composites decreased with the addition of h-BN and at shallow angles of impingement and high temperature. Among the investigated composites, SiC-4 vol% BN composites exhibited the least erosive wear at a given temperature and impingement angle, while the maximum erosive wear obtained for monolithic SiC ceramics at 25 °C and 800 °C. Fracture and deformation of SiC grains along with the pull-out of BN platelets are identified as the major mechanisms of material removal for the investigated SiC-BN composites. The presence of SiO2, B2O3 or SiO2·B2O3 phases is observed on the surface of composites eroded in high temperature conditions.

Solid Particle Erosion Behaviour and Protective Coatings for Gas Turbine Compressor Blades—A Review

Gas turbines (GTEs) are often utilised in harsh environments where the GT components, including compressor vanes and rotor blades, are subject to erosion damage by sand and dust particles. For instance, in a desert environment, the rate of damage made by solid particles erosion (SPE) becomes severe, and therefore results in degradation to the GTE parts, lowering the cycle efficiency, reducing the device lifetime, and increasing the overall cost of the operation. As such, understanding the erosion mechanism caused by solid particles and the effects associated with it is crucial for selecting the appropriate countermeasures and maintaining the system performance. This review paper provides a survey of the available studies on SPE effects on GTEs and surface protective coatings. Firstly, the ductile and brittle SPE mechanism is presented, as well as the ductile-brittle transition region. Then, an in-depth focus on the parameters associated with the SPE, such as particles properties and impingement conditions, is introduced. Furthermore, the existing theoretical models are shown and discussed. Afterwards, erosion resistant coating materials for surface protection and their selection criteria are covered in the review. Finally, the gap in knowledge and future research direction in the field of SPE on GTEs are provided.

Experimental investigation of mechanical and erosion behavior of eggshell nanoparticulate epoxy biocomposite

In the present work, the mechanical and the tribological properties of eggshell nanoparticulate epoxy biocomposite were studied. The nanoparticles of eggshell were synthesized by planetary ball milling technique. Synthesized eggshell nanoparticulate were characterized with the aid of Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), X-ray diffraction analysis, and Fourier Transform Infrared (FTIR) Spectroscopy. Fabrication of eggshell nanoparticulate epoxy biocomposite was done by hand lay-up technique with different weight percentages (1 wt%, 2 wt%, 3 wt%, 4 wt%) of eggshell nanoparticles. To examine the solid particle erosion behavior of eggshell nanoparticulate epoxy biocomposite, four different impact angles (30°, 45°, 60°, 90°) and three different velocities (101 m s−1, 119 m s−1, 148 m s−1) were chosen. The effect of eggshell nanoparticles incorporation on the tensile properties, hardness, and the flexural properties was also investigated. The fractured surfaces of the tensile test, flexural test, and erosion test samples were examined with a SEM for morphological analysis. It was found that the eggshell nanoparticulate addition has a fruitful effect on tensile and flexural strength. The maximum tensile strength was found for 2 wt% nanoparticles addition, while the maximum flexural strength was found for 3 wt% of nanoparticles addition. The sand erosion study established a maximum wear rate at 60° of impact angle. The maximum erosion resistance was found in 2 wt% of eggshell nanoparticulate concentration.

Solid particle erosive wear behaviour of Eulaliopsis binata fiber reinforced epoxy composite

In the present work, Eulaliopsis binata, a natural fiber collected from the eastern part of India is taken as a reinforcement with epoxy resin to develop a new class of polymer composite material, which has been unexplored till date for tribological applications in the composite industry. Different characterization studies of the fiber such as SEM, EDS, XRD are carried out to astern its potential to be used as a fiber in composite. Short Eulaliopsis binata fiber of different weight percent (10, 20, 30, and 40) is incorporated in neat epoxy and polymer composites are fabricated using the hand lay-up method. Solid particle erosion behavior of the fabricated composites is studied with four different impact velocities (48, 72, 82, 116 m/s) and impinging angles (30°, 45°, 60°, 90°). Improved erosion wear resistance is exhibited by the composites after the addition of Eulaliopsis binata fiber to neat epoxy. In addition, the inclusion of fiber altered the erosion behavior of neat epoxy from brittle to semi ductile nature. The impact velocity of the erodent particles also shows significant effect on the erosion behavior of the developed composites. The eroded surfaces of the worn samples are analyzed with SEM to ascertain the failure mechanism of the developed composites.

Influence of B4C/BN on solid particle erosion of Al6061 metal matrix hybrid composites fabricated through powder metallurgy technique

This work investigates and elucidates the influence of B4C and BN reinforcements on the solid particle erosion behavior of Al6061/B4C/BN metal matrix hybrid composites fabricated through the powder metallurgy technique. The metal matrix hybrid composites with reinforcement content of (2, 4, 6, and 8 wt %) B4C, and 2 wt% BN was fabricated by compacting the mechanically alloyed powders within closed circular cavity compaction die at 800 MPa pressure and subsequently sintering them at 600 °C for 3 h. The morphology of milled powders and surface profiles of samples before and after erosion were examined by X-ray diffraction, scanning electron microscope, energy-dispersive X-ray spectroscopy, elemental mapping, and surface roughness tester. The composites showed a maximum compressive strength of 249 MPa and maximum hardness of 184HV. To determine the erosion rate, various control parameters like reinforcement content, erodent velocity, erodent discharge rate and angle of impingement were considered. Taguchi's L16 (44) orthogonal array-based design of experiments was used to govern the optimum parameter settings, which led to the minimization of the erosion rate. Further, for obtaining the best response from solid particle erosion trails, the whole process was analyzed by multiple linear regression model to establish a relationship between the input and output parameters. Finally, nature-inspired, robust evolutionary strategy antlion optimization (ALO) was used for finding out the optimal parameters for the minimum erosion rate, which were found out to be 8 wt % B4C reinforcement, 80 ms−1 erodent velocity, 8 gmin-1 erodent discharge rate and 45° angle of impingement. Among all the parameters used for the erosion test, impact velocity is the most significant factor in determining the erosion rate.

Artificial Neural Network and Response Surface Methodology Based Analysis on Solid Particle Erosion Behavior of Polymer Matrix Composites.

Polymer-based fibrous composites are gaining popularity in marine and sports industries because of their prominent features like easy to process, better strength to weight ratio, durability and cost-effectiveness. Still, erosive behavior of composites under cyclic abrasive impact is a significant concern for the research fraternity. In this paper, the S type woven glass fibers reinforced polymer matrix composites (PMCs) are used to analyze the bonding behavior of reinforcement and matrix against the natural abrasive slurry. The response surface methodology is adopted to analyze the effect of various erosion parameters on the erosion resistance. The slurry pressure, impingement angle and nozzle diameter, were used as erosion parameters whereas erosion loss, i.e., weight loss during an erosion phenomenon was considered as a response parameter. The artificial neural network model was used to validate the attained outcomes for an optimum solution. The comparative analysis of response surface methodology (RSM) and artificial neural network (ANN) models shows good agreement with the erosion behavior of glass fiber reinforced polymer matrix composites.

Studies on solid particle erosion behaviour of D-Gun sprayed WC-Co, Stellite 6 and Stellite 21 coatings on SAE213-T12 boiler steel at 400 °C temperature

Erosion wear of boiler tubes occurs from room temperature to high temperature and is accelerated by oxidation and hot corrosion above 400 °C temperature. The demand for hard coatings compatible in improving erosion, oxidation and hot corrosion resistance while maintaining the desired mechanical properties of the base material is increasing with the advancement of technology. In this work, WC-12Co coating, Stellite 6 coating and Stellite 21 coatings have been deposited on SAE213-T12 boiler steel using a Detonation gun (D-gun) spray method, and their erosion performances have been evaluated at 400 °C temperature using an air jet erosion tester. The erosion tests have been carried out using the alumina erodent particles at 30° and 90° impact angles. The surfaces of the as-sprayed coatings and the specimens eroded at 400 °C temperature were analysed using a scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscope (EDS). Stellite 21 coating has shown comparatively lower erosion rate than the Stellite 6 and WC-Co coatings at 400 °C temperature attributed to the formation of protective oxides of chromium and cobalt at 400 °C. The effects of microhardness and temperature on the erosion behaviours of the coatings at 400 °C temperature are discussed. The oxide layers of chromium and cobalt and accumulation of hard phases of nickel, molybdenum and carbon contributed in the protective behaviour of the deposited Stellite 6 and Stellite 21 coatings at 400 °C. The oxidation enhanced erosion wear is observed at 400 °C temperature for all the coatings.

Investigation of Solid Particle Erosion Behaviour on Erosion Shield of a Helicopter Rotor Blade

Bu calismada, AISI 1020 celik ve Ti-6Al-4V titanyum alasim malzemelerinin kati partikul (parcacik) erozyon davranislari deneysel ve sayisal olarak incelenmistir. Deneyler ve sayisal simulasyonlar, farkli partikul carpma hizlari (100, 127, 170, 210, 250 m/s) ve acilari (20, 30, 45, 60, 90°) icin gerceklestirilmistir. Bununla birlikte, ayni malzemelerin bir helikopter pali asinma kalkanindaki erozyon performanslari, 0° hucum acisi ve 230 m/s carpma hizi sartlarinda MIL-STD-3033 standartina gore yapilmisken sayisal erozyon analizleri Eulerian-Lagrangian yaklasimli ayrik faz metodu ve ampirik erozyon esitligi kullanan ticari ANSYS_Fluent 15.0 paket programi ile gerceklestirilmistir. Calismadan elde edilen sonuclara gore, sayisal sonuclar deneysel veriyle iyi derecede uyumlu ve AISI 1020 celiginin kalkan yuzeyindeki erozyon performansi Ti-6Al-4V alasim malzemesinden daha iyi elde edilmistir.

Erosion Analysis on Copper Fly-Ash Composite

In the present study, solid particle erosion behaviour on copper – fly ash composite is studied. Composite with addition of 2.5 (wt.%) fly ash as reinforcement is prepared through powder metallurgy(P/M) technique. Solid particle erosion studies were carried out by varying the input parameters such as erodent velocity and erosion time. The results revealed that addition of fly ash reduced the resistance to erosion.

The effect of nanoclay particles on the incubation period in solid particle erosion of glass fibre/epoxy nanocomposites

During erosion tests of glass fibre/epoxy nanocomposites, an incubation period emerged because of the embedding of abrasive particles into the target material. In this study, the effect of this period on solid particle erosion behaviour was investigated for glass fibre/epoxy composites with the addition of nanoclay. The surface erosion characteristics of the composites were obtained by solid particle erosion tests using angular alumina particles with a size on the order of 400 μm as the erodent. The tests were conducted using impact velocities of ~23 or ~34 m/s and impingement angles of 30°, 60° or 90° as operating conditions. The eroded surfaces were examined using a scanning electron microscope to characterise the incubation mechanisms taking place in the nanocomposites. The glass fibre/epoxy composite without nanoclay (the pure test specimen) had the highest erosion resistance when compared to the composites with a nanoclay additive in ratios between 1% and 3% by weight. The findings of this study indicate that the agglomeration and weak compatibility of nanoclay, glass fibre and epoxy affected the results.

Effect of various factors on solid particle erosion behavior of degraded 9Cr-1MoVNb steel with experiment design

The experimental design method was applied to study the effects of impact velocity, impact angle, and erodent particle amount on the solid particle erosion properties of 9Cr-1MoVNb degraded at high temperatures for a long time. The microstructural degradation and surface damage were analyzed by scanning electron microscope, energy spectrum, X-ray diffraction, and three-dimensional microscope. The largest effect on the erosion behavior was an impact velocity followed by impact angle, erodent particle amount, and microstructural degradation. Despite that the surface hardness of 9Cr-1MoVNb was reduced by up to 30% due to microstructural degradation, the effect on the erosion behavior was not significant. Finally, the regression model consisting of the functions of the factors and erosion mechanism were proposed.

Solid particle erosion behavior of laminated ceramic structures

Often ceramics employed for structural applications have to operate in harsh environments withstanding also solid particle erosion phenomena. Enhanced surface toughness and wear resistance of ceramic components can be achieved by laminated hybrid composites owing to the compressive residual stresses that can be generated into the surface by suitably combining the thermo-physical features of the different materials.In this work the superior solid particle erosion resistance of symmetrical Al2O3 and Al2O3–ZrO2 laminated composites compared to homologous Al2O3 bulk material has been experimentally assessed. Furthermore, based on the experimental results an heuristic solid particle erosion model able to correctly predict the erosion rate when testing conditions change has been proposed.

Erosion Studies of D-Gun-Sprayed WC-12%Co, Cr3C2-25%NiCr and Al2O3-13%TiO2 Coatings on ASTM A36 Steel

Solid particle erosion studies were conducted in simulated coal-fired boiler environment in order to compare the erosion behavior of three different types of detonation gun (D-Gun)-thermally-sprayed coating powders, i.e., WC-12%Co, Cr3C2-25%NiCr and Al2O3-13%TiO2 on ASTM A36 steel and bare ASTM A36 steel. Erosion studies were conducted by using an air jet erosion test rig at impact angles of 45°, 60° and 90°. During the erosion studies, weight loss and erosion rates in terms of volume loss (mm3/g) were determined by using an optical profilometer. WC-12%Co-coated specimens exhibited the behavior closer to the behavior of ductile materials, whereas Cr3C2-25%NiCr- and Al2O3-13%TiO2-coated specimens exhibited the typical behavior of brittle materials. All the three different types of D-Gun-sprayed coating powders had successfully protected the ASTM A36 steel from solid particle erosion at an impact angle of 45°. Out of the three different types of coatings, two coatings, i.e., WC-12%Co and Cr3C2-25%NiCr, had successfully protected the ASTM A36 steel from solid particle erosion at impact angles of 60° and 90°. This paper evaluates the solid particle erosion behavior of bare and coated ASTM A36 steel which will be helpful in choosing the suitable coating for induced draft fan applications.

Effect of NiCr content on the solid particle erosion behavior of NiCr-Cr3C2 coatings deposited by atmospheric plasma spraying

Homogeneous coatings cannot meet the overall erosion-resistance requirements for an entire blade since materials present different erosion resistances at various impact angles. In this work, NiCr-Cr3C2 coatings with different NiCr contents were prepared on FV520B steels through atmospheric plasma spraying (APS) by using a double-channel powder feeder. The composition and microstructure of the as-sprayed coatings were examined by SEM, EDS, and XRD analyses, and microhardness was determined by microhardness tests. The erosion performance of NiCr-Cr3C2 coatings under different testing conditions (impact angle, solid particle size, solid particle velocity, and NiCr contents) were further evaluated with a gas–solid two-phase testing machine. Furthermore, the erosion wear mechanism of NiCr-Cr3C2 coatings with different NiCr contents at various impact angles was investigated. The results showed that the phase distribution inside the NiCr-Cr3C2 coatings became uneven with the increased NiCr content, leading to the fluctuation of microhardness. The erosion rate of 25 wt% NiCr-Cr3C2 coating initially increased and then decreased with increasing impact angle and solid particle size. The erosion rate was also improved rapidly with the increased erosion velocity for all impact angles. It was found that at low impact angles, the erosion resistance of NiCr-Cr3C2 coatings was increased with higher ceramic content because of the micro-cutting failure. By contrast, at medium and high impact angles, the erosion resistance of the coating could be improved by increasing metal content since coatings are eroded through fatigue spalling and rigid fracture.

Experimental investigation on solid particle erosion behaviour of glass/epoxy Quasi-isotropic laminates

The erosion behaviour of glass/epoxy quasi-isotropic laminates were investigated using Aluminium Oxide as erodent. Mass loss of the target material was used to estimate the erosion rate. An erosion rate prediction model was developed using Response Surface Methodology by considering impact angle, impact velocity and feed rate as the input variables. Analysis of variance of the results predict that impact angle and velocity were the major independent parameters influencing the erosion rate. Higher impact angle and lower feed rate exhibited high erosion rate; lower velocity and high feed rate resulted in lower erosion rate. Surface morphology of the specimens with low and high erosion resistance were studied using scanning electron microscopic technique.