Solid Particle Erosion Tests Research Articles

Erosion performance of direct-aged Al2O3-reinforced plasma-sprayed composite coatings at high-temperature conditions

The present investigation evaluates the influence of furnace heat-treatment (HT) on the microstructure, microhardness, fracture toughness and erosion resistance of three plasma sprayed composite coatings: a Inconel625–30 wt% micron-sized Al2O3 (In625-MHT) coating, a Inconel625–30 wt% nano-sized Al2O3 (In625-NHT) coating and a Inconel625–15 wt% micron-sized Al2O3 + 15 wt% nano-sized Al2O3 (In625-BHT/bimodal) coating. High temperature solid particle erosion tests were conducted at 900 °C temperature and with at two different impingement angles (90 and 30) in simulated environment using standard erosion-test rig. Coatings were subjected to detailed mechanical and microstructural analysis in order to better understand their erosion mechanism and structure–property correlation. By healing pores and cracks, the furnace HT increases the coatings’ erosion resistance in the order of In625-BHT, In625-NHT, and In625-MHTcoating. In addition, the mechanical properties of In625-BHT coating like porosity (1.0 ± 0.09%), micro-hardness (1299 ± 25Hv) and fracture toughness (5.9 MPa√m) are significantly improved after HT. The presence of grooves and lips on the surfaces of uncoated substrates provides clear evidence that the erosion mechanism involves the combined processes of micro-ploughing and micro-cutting indicating ductile erosion mode. However unimodal and bimodal composite coatings demonstrated a brittle erosion mode.

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.

Effect of filling materials on the tribological performance of polytetrafluoroethylene in different wear modes

AbstractAs it is known, Polytetrafluoroethylene (PTFE) is one of the most preferred polymeric materials for tribological applications. This study investigates the performance of PTFE and its composites under different tribological conditions. The effects of short glass fiber (GF), carbon particle (CP) and bronze particle (BP) reinforcement agents and their hybrid filling with molybdenum disulfide (MoS2) on sliding, erosive and abrasive wear were examined. Sliding tests were carried out with a ball‐on‐disc test apparatus, erosive wear tests were carried out with solid particle erosion and abrasive wear tests were carried out with a scratch test. It has been found that reinforcement agents improve sliding and abrasive wear resistance but worsen the erosion resistance. The hardness and contact angle of the samples were associated with their wear performances. Topographic and morphological analyzes of worn surfaces were performed using optical profilometer and scanning electron microscopy (SEM), respectively, and wear mechanisms were discussed.Highlights Filling materials (glass fiber, carbon particle and bronze particle) increase the adhesion and abrasion resistance of PTFE, while decreasing its erosion resistance. The effect of hybrid addition of MoS2 solid lubricant on wear performances depends on the type of filler. There is a correlation between surface properties (hardness and contact angle) and wear performances. Optical profilometer and scanning electron microscopy were used to examine wear mechanisms.

Comparison of the Erosive Wear Resistance of Ductile Cast Iron Following Laser Surface Melting and Alloying

This article presents research results on the influence of the laser surface melting and alloying processes on the erosive wear resistance of ductile cast iron. For the research, an EN-GJS 350-22 ductile cast iron surface was laser-melted and laser-alloyed with titanium powder in an argon and nitrogen atmosphere. Solid-particle erosion tests were carried out on the laser-melted and -alloyed surface layers and the base material according to the ASTM G76-04 standard with 30° and 90° impingement angles. The erosive wear resistance results were correlated with Vickers hardness and microstructural test results with the use of SEM (scanning electron microscopy), TEM (transmission electron microscopy), EDS (energy dispersive spectroscopy), and XRD (X-ray diffraction). The mechanisms of erosive wear were also analyzed for the laser-treated surface layers and the base material. The research showed that the laser melting and alloying processes with titanium powder had a positive effect on the hardness and erosive wear resistance of the ductile cast iron surface due to microstructure modification. Moreover, despite the lower hardness of the laser-alloyed surface layers, their composite microstructure had a positive impact on the erosive wear resistance in comparison to the laser-melted surface layers.

Parametric appraisal and wear prediction of hybrid composites using an integrated soft computing approach

AbstractThis article reports on the implementation of artificial neural network (ANN) and statistical methods to analyze and predict the erosion performance of titania (TiO2) filled ramie‐epoxy based composites. These hybrid composites are prepared by conventional hand lay‐up route and subjected to solid particle erosion tests as per Taguchi's L27 orthogonal array. The effects of different control factors on erosion rate of these composites are studied using Taguchi method. It reveals that impact velocity and filler content have significant effect on the erosion wear rate followed by other least significant factors. The individual effect of each control factor while keeping other factors constant is ascertained by performing steady state erosion experiments. Further, a computational model based on ANN is used as a tool to effectively predict the erosion rates of the composites. The results show that the predicted values are in reasonably good agreement with the experimental ones with an accuracy of 90% and relative error lying within a range of 1%–10%. Further, the trained ANN model is validated by considering the erosion rates obtained during steady state erosion process as the input parameter. The possible mechanisms causing the wear loss are identified using electron microscopy.Highlights Successful fabrication of titanium oxide reinforced hybrid composites. Steady state erosion experiments are performed. Erosion rates are predicted using ANN and compared with the experimental data. Wear loss mechanisms are identified using electron microscopy.

Enhanced solid particle erosion resistance of nanocrystalline Ni-W coatings through multilayer approach

Electrodeposited nanocrystalline Ni-W alloy coatings are projected as potential alternatives for hard chrome (HCr) coatings owing to their comparable hardness and superior corrosion resistance. However, the limited strain hardening ability of the nanocrystalline Ni-W coatings manifests in their poor resistance towards solid particle erosion involving a high strain-rate (>103 s−1) deformation. In the present study, a novel microstructural engineering strategy has been implemented to enhance the strain hardening ability of the nanocrystalline Ni-W coatings without compromising on their strength/hardness. Ni-W multilayer coatings composed of alternatively stacked soft (2.6 GPa) and hard (8.5 GPa) Ni-W layers were developed using the pulse reverse electrodeposition technique. Further, to investigate the effect of individual layer thickness (λ), multilayer coatings with different λ were deposited. Solid particle erosion testing using the angular SiO2 particles showed that the multilayer coatings (irrespective of λ) exhibit superior erosion resistance compared to the homogeneous nanocrystalline Ni-15W at both oblique (θ = 30°) and normal (θ = 90°) impact conditions. The post-erosion microstructural analysis of the multilayer coatings revealed that the hard Ni-W layers undergo uniform strain (ε > 50 %) without cracking due to the constrained co-deformation imposed by the surrounding soft Ni-W layers. Therefore, the enhanced erosion resistance of the multilayer coatings is attributed to the effective dissipation of impact energy through co-deformation of the individual hard and soft Ni-W layers.

The Influence of Flame Exposure and Solid Particle Erosion on Tensile Strength of CFRP Substrate with Manufactured Protective Coating.

This paper presents the results of laboratory tests for new materials made of a carbon fibre-reinforced polymer (CFRP) composite with a single-sided protective coating. The protective coatings were made of five different powders-Al2O3, aluminium, quartz sand, crystalline silica and copper-laminated in a single process during curing of the prepreg substrate with an epoxy matrix. The specimens were subjected to flame exposure and solid particle erosion tests, followed by uniaxial tensile tests. A digital image correlation (DIC) system was used to observe the damage location and deformation of the specimens. All coatings subjected to solid particle erosion allowed an increase in tensile failure force ranging from 5% to 31% compared to reference specimens made of purely CFRP. When exposed to flame, only three of the five materials tested, Al2O3, aluminium, quartz sand, could be used to protect the surface, which allowed an increase in tensile failure force of 5.6%.

The solid particle erosion performance of tungsten inert gas yttria-stabilized zirconia - Inconel 625 composite cladding

The yttria-stabilized zirconia (YSZ) - Inconel 625 (IN625) composite cladding was deposited on a stainless steel substrate using a tungsten inert gas welding manipulator to protect it from solid particle erosion. Erosion wear tests were carried out at room temperature according to the ASTM G76-18 procedure. The surface of the tested material was exposed to a jet of alumina erodent particles at impact angles of 30 and 90°, respectively. Scanning electron microscopy images were utilized to examine the morphologies of the eroded surface and the microstructure of cladding. The erosive performance of YSZ - IN625 composite cladding was 3.5 and 2.4 times compared to the substrate at different impact angles. Improved microhardness and fracture toughness resulting from the favourable interaction between the hard ceramic YSZ particles and the IN625 matrix led to the enhanced erosion performance of composite cladding. Micro-cutting and ploughing were the predominant wear mechanisms in the substrate during the solid particle erosion test at a 30° impact angle, whereas the indentation-induced plastic deformation was domi­nant at a 90° impact angle. The results also revealed that the micro-cutting, detached splats and fissures were responsible for the wear in composite cladding at 30 and 90° impact angles.

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°.

Comparative study of anodizing and chromate conversion coatings in enhancing the wear and corrosion properties of 6063 Al alloy

ABSTRACT The present study compares the corrosion and tribological performance of anodic oxide (AO) and chromate conversion (CC) coatings deposited on 6063-T6 aluminum alloy. The goal is to determine how these treatments benefit the performance of the underneath substrate. The corrosion protection properties of the coatings were evaluated by potentiodynamic polarization measurement in 3.5 wt. % NaCl solution. The friction and sliding wear behavior of coatings were studied by pin-on-disk test and their erosion behavior was examined by air jet solid particle erosion test. The surface structure, chemical composition, roughness, wettability, and hardness of specimens were also characterized. The results showed that the AO coating with porous surface morphology was found to be thicker, rougher, and harder along with greater wettability, when compared to CC coating. Furthermore, the AO coating with polarization resistance of 6.64 × 103 Ω.cm2 enhanced the corrosion resistance of the substrate more than 8 times. In addition, the AO coating under dry and wet sliding conditions reduced the aluminum alloy substrate wear rate by about 80% and 52%, respectively. However, due to being more brittle, the AO coating lost more weight than the CC coating during the solid particle erosion test.

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.

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.

Submerged deflecting abrasive waterjet peening for improving the surface integrity and solid particle erosion resistance of Ti-6Al-4V alloy

Waterjet peening is a promising new surface treatment technology, which is increasingly used to improve a metal's surface integrity and mechanical properties. In this study, the surface integrity and solid particle erosion (SPE) resistance of Ti-6Al-4V alloy treated with submerged deflecting abrasive waterjet peening (SDA-WJP) at different standoff distances (D = 3, 6, and 9 mm) were investigated. First, the surface integrity of specimens before and after SDA-WJP treatment was compared, including microstructure, surface roughness, micromorphology, microhardness, and compressive residual stress (CRS). The test results showed that the SDA-WJP-treated specimens formed refined grain deformation layers of 8–24 μm and minimum roughness of Ra = 0.28 μm and Sa = 0.55 μm. The thicknesses of the refined grain hardening layer and CRS field were 140–180 and 120–200 μm, respectively. Finally, the SPE behavior and mechanism of the samples before and after SDA-WJP treatment were studied in the SPE test. The highest increase in SPE resistance was 51 % under different SDA-WJP processes. The microscopic morphology of the eroded surface was observed by scanning electron microscopy. The shallow embedding depth of the particles on the eroded surface after SDA-WJP treatment led to difficult platelet formation for removal. The introduced refined grain hardening layer and CRS field were critical in preventing micro-crack initiation and propagation. This work optimizes the SDA-WJP process parameters for improving the surface integrity and SPE resistance of Ti-6Al-4V alloy, thus providing a reference for the application of SDA-WJP for the improvement of the SPE resistance of aero-engine blades.

Effect of TiC/RHA on solid particle erosion of Al6061 hybrid composites fabricated through a 2-step ultrasonic-assisted stir casting process

The development of high wear/erosion resistance materials for defense application is found to be a challenging task among the researchers. The current study investigated the reinforcement effect of TiC and Rice husk ash (RHA) on Al6061 hybrid composites made using a two-step ultrasonic-assisted stir casting process. Four distinct Al6061 hybrid composites were created with varying TiC weight percentages (3, 6, 9, and 12 wt.%). RHA weight percentage was kept constant at 3%. The solid particle erosion test was carried out on each composite using a Taguchi L27 (33) orthogonal array. Experiments were conducted by varying the erodent particle impact angle, erodent velocity, and erodent discharge rate. The effect of each parameter on the erosion rate of the TiC/RHA Al6061 composite was discussed. The composite containing 12% TiC and 3% RHA showed improved erosion resistance. It was found that on increasing the TiC addition in the composite resulted in an increase in erosion resistance. SEM images were used to examine the surface failure on the composites caused by erodent impact.

Erosion wear response of ramie‐epoxy composites using artificial neural network integrated with Taguchi technique

AbstractThis paper aims on evaluating the erosion wear behavior of epoxy composites reinforced with ramie fibers. The possibility of reinforcing ramie fiber to improvise the wear resistance of epoxy is investigated in this study. Composites are fabricated by reinforcing multiple layers of woven ramie fiber mats into epoxy resin using conventional wet lay‐up technique and erosion wear trials are conducted using solid particle erosion test setup. Taguchi analysis is done to assess the relative significance of each of the factors influencing the erosion rate using L16 orthogonal array. The analysis reveals that the impact velocity followed by impingement angle are the most significant control factors affecting the erosion wear rate of ramie‐epoxy composites. Steady state erosion analysis is done to ascertain the effect of each of the significant factors while keeping other factors fixed. Further, an analytical and predictive model based on the principle of neural computation is used to predict the rate of erosion wear of the composites and the obtained results are compared with the experimental outcomes. The worn morphologies of the eroded surfaces of the composites are studied and analyzed to identify possible mechanisms causing wear.

High temperature erosion performance of NiCrAlY/Cr2O3/YSZ plasma spray coatings

ABSTRACT The current investigation's objective was to assess the air jet erosion tester's ability to measure the erosive behaviour of plasma sprayed coatings on titanium-15 alloy. 65% NiCrAlY, 30% Cr2O3, and 5% YSZ make up the coating's chemical composition. A study of microstructure and phases was carried out. Microhardness and adhesive strength have both been measured in this work. With impact angles of 30° and 90° at 300°C, 500°C, and 700°C, Al2O3 erodent was utilised in a solid particle erosion test. An optical profilometer was used to calculate the erosion volume loss. The coating erosion resistance was found to be higher than the substrate sample for the test temperature that was employed, and this was more obvious at higher impact angles and higher temperatures The ductile character of the coating is seen in the contour of the deteriorated coating surface.

The influence of HV-APS process parameters on microstructure and erosion resistance of metalloceramic WC-CrC-Ni coatings

This article presents an analysis of the effect of high velocity plasma spraying (HV-APS) parameters of WC-CrC-Ni powder. Plasma spraying processes were carried out using a three-electrode Axial III type torch with central powder injection, in which a supersonic nozzle with a diameter of 5/16 inch was installed. The following were taken as variable parameters: power current per electrode (140, 160, 180A), hydrogen flow rate (10, 20, 30 NLPM) and powder feed rate (15, 20, 25 g/min). The obtained coatings were characterized by thicknesses exceeding 200 μm and their porosity was very low (<1%), similar to those obtained by the HVOF method most commonly used for spraying carbide coatings. The obtained coatings were characterized by hardness in the range of 800–950 HV0.5 - depending on spraying parameters. The solid particle erosion test showed that the WC-CrC-Ni coating - regardless of the spraying parameters - has good erosion resistance. The analysis of the obtained test results indicates that the use of the HV-APS process allows producing carbide coatings with properties similar to those obtained in the HVOF spraying method and significantly better compared to conventional plasma spraying (APS).

Structure and properties of laser-cladded Inconel 625-based in situ composite coatings on S355JR substrate modified with Ti and C powders

Abstract This article presents the research results on the production of laser-cladded Inconel-625 in situ composite coatings on the S355JR substrate by addition of titanium and graphite powders to pure Inconel 625 alloy powder mixture for increased hardness and erosive wear resistance of the coatings. The research featured in the article includes penetrant testing, macro-, and microscopic observations of produced coatings, phase and chemical composition analysis, hardness and solid particle erosion tests. The results showed that the addition of titanium and graphite powders resulted in the composite microstructure formation by precipitation of Ti, Nb, Mo, and C-rich blocky and eutectic particles during crystallization. The conducted tests revealed that the microstructure change resulted in an increase in hardness and erosive wear resistance by 27% and 30%, respectively.

Improving the Erosion Behavior of Inconel 625 Substrate by PTA-Deposited Stellite6/B4C Composite Cladding

The purpose of this study was to improve the erosion behavior of Inconel 625 alloy by plasma transferred arc-deposited stellite6/B4C composite cladding. For this purpose, 5 wt.% of boron carbide was added to the stellite6 clad. Phase analysis and microstructure evaluation were conducted by Optical Microscope, Field Emission Scanning Electron Microscope (FESEM), and Energy-dispersive Spectroscopy (EDS). Solid particle erosion tests with silica particles at 30˚ and 90˚ impact angles were performed to study the erosion behavior. Eroded surfaces were observed by SEM. Investigations showed that the addition of boron carbide particles caused finer microstructure in composite cladding. Moreover, hardness increased with adding boron carbide. Maximum erosion resistance was achieved at 30˚ impact angle. The weight loss of composite cladding were 20 % and 33 % compared to those obtained in Inconel 625 substrate and stellite6 cladding, respectively. The weight loss of the claddings and substrate showed negligible difference at 90˚ impact angle. The dominant mechanism of erosion for composite cladding at 30˚ impact angle was suggested to be cutting and detachment of reinforcing particles. Crater formation was found the predominant mechanism of erosion at 90˚ impact angle.

High temperature erosion behaviour of high-velocity oxy-fuel sprayed CNT/NiCr-Cr3C2 composite coatings

In the present work, the effect of different weight percentages of carbon nanotubes on the high-temperature erosion behaviour of NiCr-Cr3C2 composite coatings is demonstrated. The high-velocity oxy-fuel (HVOF) spraying process was employed for the deposition of coatings on ferritic low-alloy steel (SA-213 T12). The solid particle erosion test of the coating with and without carbon nanotubes was conducted at a temperature of 600 °C with 30, 45, 60, and 90° impact angles using Al2O3 erodent particles. This work exhibited high erosion resistance for composite coatings with the highest CNT content of 7 %. However, as the impact angle was increased from 30° to 90°, the erosion rate of all coatings, irrespective of CNT content, increased. An Optical 3-Dimensional Profilometer was used to estimate lower crater depths for lower impact angles and deeper crater depths for higher impact angles observed through surface topography. The effect of the addition of CNTs in NiCr-Cr3C2 coatings resulted in a reduction in weight loss and erosion rate at different angles of impingement working under high temperatures. The outstanding mechanical properties of CNTs impart improved erosion resistance.