Solid Particle Erosion Behavior Research Articles

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

On the sliding wear and solid particle erosion behaviour of HVOF-sprayed CoNiCrAlY coatings and NiCrCoTi substrates in dependence of the oxidation dwell time at 900 °C

In high temperature sections up to 900 °C overlay MCrAlY coatings are frequently used to increase the life time of Ni based components in technical applications. Beside oxidation protection, coatings resistance to sliding wear and solid particle erosion is required during different service operation regimes. In the present work the focus is set on the wear behaviour of HVOF-sprayed CoNiCrAlY coatings deposited on a NiCrCoTi substrate (Nimonic 90) and of uncoated substrate, before and after oxidation for different dwell times up to 1200 h at 900 °C. The samples were investigated in respect to their behaviour under dry sliding wear conditions and solid particle erosion at ambient temperatures. Sliding wear was tested by means of pin-on-disc method. Solid particle erosion was conducted using an in-house developed air jet erosion testing rig. Moreover, microhardness indentations HV 0.1 were performed in order to determine changes of materials hardness depending on the heat exposure. Microstructural and phase analysis was performed by means of scanning electron microscopy (SEM) combined with energy-dispersive X-ray spectroscopy (EDX) and by X-ray diffraction (XRD). Confocal laser scanning microscopy (CLSM) was used to measure thickness, hardness indentations and wear degree of the surfaces. Samples mass losses were considered as well. Coatings performance is pointed out in comparison with that of the uncoated NiCrCoTi substrate, set to same conditions. It could be shown, that the sliding wear and particle erosion behaviour of the investigated samples strongly depends on materials microstructure and chemical composition. The accelerated oxidation reaction kinetics of NiCrCoTi substrate lead to the formation of a thicker oxide scale, which exhibited protective effects of a glaze-layer during sliding wear. However, the oxide scales do not benefit the protection of solid particle erosion.

Solid Particle Erosion Behavior of La2Ce2O7/YSZ Double-Ceramic-Layer and Traditional YSZ Thermal Barrier Coatings at High Temperature

Thermal barrier coatings (TBC) used for turbine blades are indispensable for the most advanced aero-engines due to their excellent thermal insulation performance. Solid particle erosion (SPE) at high temperatures is one of the most critical factors in TBC failure. The high-temperature SPE failure behavior of TBC on circular sheets and turbine blades was investigated in this paper at erosion angles 60° and 90°. The high-temperature thermal shock behavior of TBC was also studied as the control group. The SPE failure mechanism of TBC is attributed to the spallation and thickness decrease of TBC. The formation of thermally grown oxide is the main reason for the TBC spallation, while the thickness decrease of TBC is due to the impaction of solid particles by near-surface cracking. The erosion angle is critical to the failure behavior of TBC, and TBC is more susceptible to SPE at an erosion angle of 60° than that at 90° because of the additional shear stress. Furthermore, a La2Ce2O7/YSZ double-ceramic-layer TBC was designed and deposited on turbine blades. The experimental results indicate that this type of double-layer TBC has more excellent performance under SPE than traditional YSZ TBC.

Investigation of solid particle erosion behavior of Al-Al2O3 and Al-ZrO2 metal matrix composites fabricated through powder metallurgy technique

The proposed research article presents an experimental investigation of solid particle erosion wear of Al2O3 and ZrO2 ceramic oxide reinforced metal matrix composite developed via powder metallurgy method. Two different kinds of metal matrix composites, Al-Al2O3 and Al-ZrO2 were developed with different proportions (0, 2.5, 5 and 10 wt%) of micro-sized ceramic oxide reinforcement powders. Vickers Hardness (HV), experimental densities of sintered samples, XRD and EDS were evaluated for mechanical characterization of fabricated metal matrix composites. Solid particle erosion wear tests were carried out at impingement angles 30–90° at varying set impact velocities of 30–90 m/s on air-jet erosion wear test rig using tiny micro-sized Al2O3 powders as an erodent. Air–jet erosion experiments were conducted as per the G76 standard for study of the steady-state erosion wear. ANOVA test revealed that wt% of reinforced contents was a significant parameter followed by impact velocity. 5 wt% of ZrO2 was observed to be the best wt% of reinforcement of all the combination of fabricated composites.

Study of solid particle erosion of thermal spray coated and uncoated cobalt based superalloy

Erosion resistance of turbine components can be improved using various thermal spray coatings techniques, in the present work HVOF spray coating technique is used to deposit tungsten carbide alloy powder composition (30%WC-CO+70% NiCrBSi) on cobalt based seperalloy Superco-605. The coating is characterized using scanning electron microscope (SEM). Solid particle erosion behaviour of coating is evaluated at 30o, 60o and 90o angle of impact at room temperature, silica sand of size 150?m is used as erodent, particle feed rate maintained is 4.8gm/min, rate of erosion and steady state volumetric erosion rate is determined and results are plotted, from the plots it is indicating that the rate of erosion for coated samples are higher compared to uncoated samples, and there is higher erosion rate at 90o angle of impact and tends to be low for impact angle of 30o indicating brittle mode of erosion.

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.

High-Temperature Solid Particle Erosion Behavior of Laser Powder Bed Fused Inconel 718

Abstract The failure of turbine blades due to solid particle erosion is a serious concern in aviation applications. This research investigates the solid particle erosion behavior of laser powder bed fused IN718 alloy for the effect of temperature (400 °C, 500 °C, and 600 °C) and impact angle (45 deg and 90 deg) in a gas-jet erosion setup. The erosion rate progressively increased with the test temperature and it is significantly higher in the 45 deg eroded samples. The eroded samples were characterized for residual stress distribution, surface topography, and surface roughness using X-ray diffraction analysis (XRD), scanning electron microscopy (SEM), and 3D optical profilometer. Compressive residual stress is evident in all eroded samples, and higher residual stress is measured in the 90 deg eroded samples. Ploughing, crater lip formation, and cracking are the erosion features observed in the 45 deg eroded samples. In comparison, localized plastic deformation, platelet mechanisms, and cracked ridges are observed in the 90 deg eroded samples. Crack formation at 600 °C test condition is attributed to severe erosion degradation in both the impact conditions (45 deg and 90 deg). The as-printed and solution-double aged samples were thoroughly investigated for microstructure and microhardness distribution at the region parallel and perpendicular to the build direction.

Solid Particle Erosion Behaviour of Plasma-Sprayed (WC–Co)/(Cr3C2–NiCr) Coatings

Solid Particle Erosion Behaviour of Plasma-Sprayed (WC–Co)/(Cr3C2–NiCr) Coatings

Study of environmental behavior and its effect on solid particle erosion behavior of hierarchical porous activated carbon‐epoxy composite

AbstractPorous carbon materials have versatile physical and chemical characteristics; however, these materials are not be fully exploited as reinforcements in polymer composites. The present investigation focuses on extraction of hierarchical porous carbon and its utilization in polymer composite in order to enhance the erosion wear resistance and hardness of polymer composite. The current research work also demonstrates the wear behavior of the hierarchical porous carbon epoxy composite when exposed to different environmental conditions. The attributes of hierarchical carbon have verified through different characterization techniques, further porous carbon with optimum properties has been included as reinforcement in different ratios viz. 1, 2 and 3 wt. % to make the epoxy composites. The composites were studied for their hardness, moisture absorption and erosion wear behavior at variable impingement angles (30°, 45°, 60°, and 90°) and impingement velocities (101, 119, and 148 m/s). Moisture uptake results suggests that the increase in filler percentage increased the moisture absorption, and the highest moisture absorption was reported in composite immersed in saline water environment. It was observed that addition of activated carbon particles has enhanced hardness and wear resistance of the composite. Composite with 2 wt.% particulate reinforcement was found to be the optimum percentage of reinforcement which was subjected to 82.4% less material loss that is, erosion rate at 45° impact angle compared to neat polymer. From the erosion wear results it was further noticed that moisture absorption has deteriorated the erosion wear resistance of composites resulting in high material loss.

Effect of addition of Al2O3 on the high-temperature solid particle erosion behaviour of HVOF sprayed Inconel-718 coatings

In the present study, three different coatings Inconel718 + 10 wt%Al2O3, Inconel718 + 20 wt%Al2O3 and Inconel718 + 30 wt%Al2O3, were deposited by using a high-velocity oxy-fuel (HVOF) spray process. The effect of adding Al2O3 content in the Inconel-718 matrix was analyzed for the mechanical and microstructural properties. Using an 800 °C high-temperature air-jet erosion test apparatus, the erosion behaviour of the bare and coated specimens was examined at various impact angles. The XRD (x-ray diffraction) technique for determining the phases prevalent in the powders and coatings. Scanning electron microscopy (SEM) and energy dispersive spectroscopy were used to examine the surface morphology and elemental analysis of coatings (EDS). The composite coatings with maximum alumina content (30 wt%) exhibited maximum erosion resistance with a maximum microhardness of about 801 ± 40 HV0.2. However, the coating with 20 wt% alumina showed the highest fracture toughness. The inclusion of alumina reinforcement has improved the coating’s mechanical properties as well as their erosive wear resistance.The removal of splats and micro-cracking wereidentified as theprimary material removal mechanisms at a 90° impact angle. The ploughing and micro-cutting were identified as the dominant material removal mechanisms at 30° impact angle.

Microstructural Characteristic and Solid Particle Erosion Behavior of Plasma-Sprayed Ni60/Ni-WC Composite Coating

A Ni60/Ni-WC composite coating was fabricated by the plasma spraying technology and microstructure of the coating was analyzed. Moreover, erosion resistance of the coating under different erosion angles was tested. Results demonstrated that the coating has lamellar structures and contain some pores. WC particles distribute evenly in the coating and bond well with the parent phase. When the erosion angle increase, the weight loss of the erosion-induced coating increases firstly and then decreases, showing plastic-brittle composite erosion characteristics.

Solid particle erosion behavior and failure mechanism of TiZrN coatings for Ti-6Al-4V alloy

Arc-plasma deposition technique was used to prepare coatings on a Ti–6Al–4V alloy surface due to its high coating deposition rate and superior coating-substrate bonding strength. The effects of the coatings on the erosion resistance of the alloy to solid-particle erosion at low- (30°) and high- (90°) impact angles were investigated. The results indicated that all coatings significantly improve the erosion resistance of the titanium alloy at an impact angle of 30°. It was attributed to the high microhardness and excellent bonding strength of the coatings. However, at a high-impact angle (90°), the thin monolayer coating was worn off after the erosion test and the failure mechanism of this coating was shear fracture and interface cracking of columnar crystals. With increasing of the coating thickness, the failure mechanism changed to single shear fracture and the thick monolayer coating retained the protection capability for the titanium alloy surface after this erosion. Moreover, compared with the monolayer coating, the multilayer coating as thick as the thick monolayer coating had a superior erosion resistance and slighter shear fracture under this erosion test condition. It was mainly due to the good toughness and strength, sufficiently high dynamic loading capability of the multilayer coatings.

Influence of SiC on solid particle erosion and mechanical behaviour of Al–25Zn alloy based novel metal matrix composites fabricated through stir casting technique

ABSTRACT This investigation studied the influence of SiC reinforcement (0, 10, 15 and 20 wt.%) on solid particle erosion and mechanical behaviour of novel Al–25Zn alloy metal matrix composites fabricated by the stir casting technique. The erosion wear experiments were conducted following the ASTM G-76 standard for various impact velocity, impingement angle, and erodent temperature as per Taguchi L16 orthogonal array using air jet erosion test rig with erodent silica sand particles of irregular shapes with size approximately 150 µm. The attempt has been made to establish linear and nonlinear correlations between input parameters and erosion rates. The artificial neural network and the Taguchi approach were used to identify the optimal parameter combination for the minimum erosion rate. The results show a significant alteration in properties with reinforcement of SiC content. The analysis of variance, signal to noise ratio, and morphology of eroded surfaces indicates that impact velocity is the most dominating parameter for the erosion rate among studied parameters. The erosion rate increased with the rise in impact velocity, whereas the highest erosion rate is observed with 30° impingement angle. For identical test conditions, optimum mechanical and erosion characteristics are noticed for the composite with 15% SiC.

Investigation of solid particle erosion behaviour of SS-304 under different conditions

Erosion is a multifarious phenomenon and observed to be the major cause of failure of many engineering systems including aircraft engines, power generation units and industrial equipment. In the current study, erosion tests were carried out on SS-304 steel by utilizing an air jet erosion testing rig. The erosion behaviour of austenitic stainless steel (SS-304) at different temperatures (room temperature, 200 °C and 400 °C) was evaluated. The effect of impingement angle of erodent particles on erosion mechanism was also determined. It was observed that the erosion rate of steel was higher at room temperature and decreased gradually with increase in temperature up to 400 °C. The erosion rate was also observed to be high at oblique impact angle (30°) as compared to normal impact angle (90°) indicating the ductile mode of erosion. Further scanning electron microscopy with Energy Dispersive Spectroscopy (SEM-EDS) attachment was utilized for surface characterization of eroded samples. The eroded samples show the development of lips and craters which results in plastic deformation of material.

High-Temperature Solid-Particle Erosion Behaviour of Plasma-Sprayed Fe17Cr2Ni0.18C/Cenosphere-Based Composite Coating

The present investigation deals to improve the solid-particle erosion resistance of boiler steel material. FeCrNiC and FeCrNiC with 5, 10 and 15wt.% cenosphere composite coatings were deposited on A387 Grade 22 steel using plasma spray technique. Powder and as-sprayed coatings are characterized using Scanning Electron Microscope (SEM), X-ray diffraction to study the surface morphology and cross section to study the nature of coatings deposited. Microhardness and adhesion strength of the coatings are evaluated. High-temperature solid-particle erosion behavior of these coating is evaluated at 300 oC and 600 oC at different impact angles. FeCrNiC + 15%Cenosphere designates higher hardness and adhesion strength. Convention weight change method cannot be used to validate the erosion performance due to undesirable variation. Optical profiler is used to determine erosion volume loss. The FeCrNiC coatings with the addition of cenospheres showed better erosion resistance than as-sprayed FeCrNiC and substrate. FeCrNiC + 10%Cenosphere coating shows the highest erosion resistance as compared to other coatings and substrate. Further increase in cenosphere percentage leads to reduction in erosion resistance due to predominant brittle fracture. High-temperature erosion is a concurrent erosion–oxidation process which shows combination of ductile and brittle erosion mechanism.

Solid particle erosion behavior of melt-infiltrated SiC/SiC ceramic matrix composites (CMCs) in a simulated turbine engine environment

The erosion behavior of a melt infiltrated SiC/SiC ceramic matrix composite was investigated under a more representative engine environment. A special experimental facility was setup to simulate the turbine engine conditions. The influence of the operating parameters such as particle velocity, particle size, temperature, erodent concentration and impingement angle were investigated. In addition, room temperature studies were also conducted under the same operating parameters for comparison. Eroded sites were investigated under the scanning electron microscope (SEM) to understand the erosion mechanisms. The results indicate that erosion rate increased with increase in particle velocity, size and temperature. Also, at shallow impact angles the CMC shown to exhibit ductile like mode of erosion as opposed to brittle fracture mode at normal impact angles was observed. The erosion rate decreased with increase in erodent concentration which may be related to a particle shielding effect.

Solid Particle Erosion Behavior of Partially Oxidized Al with NiCr Composite Coating at Elevated Temperature

The composite coating was developed and investigated the solid particle erosion performance at elevated temperature by varying impact angles. Al2O3 erodent of grit size 50 µm was used in air-jet erosion tester to investigate the resistance to erosion at RT, 200, 400, 600, and 800 °C by varying 30, 45, 60, 75, and 90° impact angles. The composite coating was deposited on MDN321 steel by plasma spray process with feedstock of “30 weight percent of partially oxidized Al powder and 70 wt.% of NiCr alloy powder.” The composite coating was characterized by bond strength, porosity, micro-hardness, and density. Volumetric erosion loss concerning temperature and impact angle was studied using SEM, EDAX, and XRD analysis. Non-contact three-dimensional optical profilometer was used to quantify the volumetric erosion loss. MDN321 steel showed better erosion resistance than composite coating at all the temperatures. Due to the formation of stable oxides at 800 °C the erosion resistance of the coating was improved.

A study of T11 boiler steel protection by cold sprayed Inconel 738 coating against high temperature erosion

The failure of boiler tubes, superheater tubes and turbine blades, due to high-temperature erosion, is a serious issue in the power generation industry. The investigation focuses on the applicability of cold sprayed Ni-based coatings for boiler tubes and turbine blades, by improving the erosion resistance of the base material. The present work includes high-temperature solid particle erosion behaviour of Inconel 738 (IN 738) coatings deposited on ASTM SA213 T11 steel substrate, by means of cold spray deposition. A comparison of the temperature effects on the erosion performance of coated and uncoated samples have been examined by an air jet erosion tester. After the erosion tests, both uncoated and coated specimens were characterised using a scanning electron microscope (SEM) and X-ray diffraction (XRD) analysis. Erosion resistance of the coating is approximately three and two times higher than T11 steel at 700°C for 30°and 90° impact angles, respectively. Consequently, cold spray IN 738 coating offers higher resistance to high-temperature erosion than that of the base steel, which is essential in a power plant environment.

Impact of Process Parameters on Solid Particle Erosion Behavior of Waste Marble Dust-Filled Polyester Composites

The aim of this paper is to provide broad information on the solid particle erosion behavior of polymeric composites using waste marble dust as the filler. Attention is paid toward the effects of test parameters, i.e., impingement velocity, filler content, striking angle, etc., on the erosion wear rate, and their failure mechanisms are discussed. Marble dust, the filler material in this work, is an industrial/construction waste generated during the processing of marble rocks and is a known air pollutant. The possibility of incorporating waste marble dust to enhance the erosion resistance of polyester is explored in this research. The parameter combinations obtained from the Taguchi’s L25 orthogonal array are used for the erosion wear trials on the composite samples. The analysis of test results reveals that impingement velocity, filler content and striking angle in that sequence have significant effect on the erosion rate. Statistical analysis is made on the test results carried out on the composite samples using different levels within the test range of the significant parameters individually keeping all other parameters constant to explore their effect more precisely on the erosion rate. Analysis of the morphologies of worn composite surfaces reveals the predominant wear mechanisms and the erosion response (ductile/brittle) of the composites. This work shows that inclusion of various fillers into polymeric composites improves the erosion resistance which would attract the researchers to find out their application as tribo-materials.