Solid Particle Erosion Wear Research Articles

Comparative evaluation of solid particle erosion resistance in milled carbon fiber‐reinforced basalt fiber epoxy composites: Impact of abrasive shape variations

AbstractThe solid particle erosive wear performance of basalt fiber‐reinforced epoxy composites with the incorporation of different percentages of milled carbon fiber fillers (0–10 wt%) is evaluated under various abrasive materials (garnet and ceramic beads) and impingement angles (30° and 90°). Erosion tests have been carried out following ASTM G76 standards using a factorial design method. The data indicate that the erosion rates, crater depths, and areas of craters are all strongly dependent on erodent material type and milled carbon fiber filler ratio. Compared to ceramic beads, garnet abrasives caused severe erosion, with erosion rates reaching approximately 500 mg/g at a 90° impingement angle without milled carbon fiber fillers. Erosion by both abrasives was significantly reduced by the introduction of milled carbon fiber fillers into the basalt fiber composites, with the erosion rate decreasing to around 100 mg/g with 3 wt% milled carbon fiber fillers. The maximum crater depth was also influenced; garnet abrasives produced craters as deep as 1000 μm without fillers at 90°, which was reduced to 451 μm with 3 wt% milled carbon fiber fillers when ceramic beads were used. Of the three factors for the erosion rate and crater depth, inorganic erodent material and ratio of carbon fiber filler were prominent, but the impingement angle effect was much smaller. Among the three factors for the erosion rate and crater depth, erodent material and carbon fiber filler ratio were prominent, while the impingement angle effect was significantly less.Highlights The garnet abrasives cause more severe erosion than ceramic beads at 90°. Composites exhibit optimal erosion resistance with 3–5 wt% milled carbon fiber fillers. Filler ratio and erodent material type significantly impact erosion rates and depths. Factors affecting wear performance identified using factorial design and ANOVA.

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.

Tribological properties and solid particle erosion wear behavior of Al2O3-13 wt%TiO2/Al2O3-PF composite coatings prepared on resin matrix by supersonic plasma spraying

Resin materials feature exceptional physical properties and inexpensive cost, but unfavorable surface characteristics, such as low wear resistance and poor erosion wear performance, render them tough to satisfy greater demands. The potential option is to prepare supersonic plasma sprayed Al2O3-13 wt%TiO2/Al2O3-phenolic resin (AT13/Al2O3-PF) coating on the surface of the resin matrix. AT13 feedstocks are classified into two types: Al2O3-13 wt%TiO2 powder prepared by the agglomeration granulation process (AT13-1) and the mixture of spherical Al2O3 and TiO2 (approximately 13 wt%) powder (AT13-2). The effect of component dispersion on mechanical and tribological characteristics of coatings was thoroughly investigated, as well as the solid particle erosion wear behavior of coatings. The results illustrated that the evenly dispersed TiO2 phase in AT13-1 coating was prone to homogenize the coating structure, resulting in better tribological characteristics than AT13-2 coating, although erosion wear performance was inferior to AT13-2 coating. The wear rate of AT13-1 coating was 1.36 × 10−5 mm3 (N m)−1, which was 1/21 times that of AT13-2 coating. At the 60° erosion angle, the high porosity of AT13-1 coating resulted in hard phase cracking or hard phase debonding. The high microhardness of AT13-2 coating reduced erosion wear at the 90° erosion angle.

Prediction of gas–solid erosion wear of bionic surfaces based on machine learning and unimodal intelligent optimization algorithm

Solid particle erosion wear is an inevitable phenomenon in industrial production, with erosion removal mass serving as a crucial metric for assessing the wear rate per unit area on the impacted surface. Developing predictive models to estimate the degree of mass removal is crucial for effectively controlling, evaluating, and preventing severe damage resulting from solid particle erosion wear. In this study, we constructed a comprehensive dataset comprising smooth and bionic surfaces, encompassing inner, outer, and planar surfaces. The dataset was used in a multifactorial erosion experiment, considering adjustable erosion angles, solid particle incident gas velocities, and solid particle diameter sizes. Through visualization and analysis of the obtained dataset, we identified optimal scenarios for bionic surface erosion resistance, offering insights for structural design against bionic erosion resistance. Furthermore, we compared machine learning algorithms to address the prediction problem, resulting in the selection of the best-performing regression algorithm, SVR (Support Vector Regression). Additionally, we compared the performance of other advanced intelligent optimization algorithms using unimodal benchmark functions, finding that HHO (Harris Hawks Optimization) emerged as the optimal choice for unimodal optimization. Building on HHO, we developed the IHHO (Improved Harris Hawks Optimization)-SVR model, using experimental data from erosion tests as the training dataset. This model can predict gas–solid two-phase flow erosion patterns, encompassing various wall types, solid particle sizes, solid incident gas velocities, and impact angles. Due to its robustness and rapid prediction capabilities, the model is expected to serve as a cost-effective tool for predicting erosion removal mass in gas–solid two-phase flow scenarios.

Research on the solid particle erosion wear of pipe steel for hydraulic fracturing based on experiments and numerical simulations

Erosion wear is a common failure mode in the oil and gas industry. In the hydraulic fracturing, the fracturing pipes are not only in high-pressure working environment, but also suffer from the impact of the high-speed solid particles in the fracturing fluid. Beneath such complex conditions, the vulnerable components of the pipe system are prone to perforation or even burst accidents, which has become one of the most serious risks at the fracturing site. Unfortunately, it is not yet fully understood the erosion mechanism of pipe steel for hydraulic fracturing. Therefore, this article provides a detailed analysis of the erosion behavior of fracturing pipes under complex working conditions based on experiments and numerical simulations. Firstly, we conducted erosion experiments on AISI 4135 steel for fracturing pipes to investigate the erosion characteristics of the material. The effects of impact angle, flow velocity and applied stress on erosion wear were comprehensively considered. Then a particle impact dynamic model of erosion wear was developed based on the experimental parameters, and the evolution process of particle erosion under different impact angles, impact velocities and applied stress was analyzed. By combining the erosion characteristics, the micro-structure of the eroded area, and the micro-mechanics of erosion damage, the erosion mechanism of pipe steel under fracturing conditions was studied in detail for the first time. Under high-pressure operating conditions, it was demonstrated through experiments and numerical simulations that the size of the micro-defects in the eroded area increased as the applied stress increased, resulting in more severe erosion wear of fracturing pipes.

Development of machine learning models for the prediction of erosion wear of hybrid composites

AbstractThis article reports on development of an adaptive framework for predicting the erosion performance of polymer composites using certain statistical and machine learning (ML) models. For this, ramie‐epoxy composites reinforced with variations (0–30 wt%) of sponge iron slag (an iron industry waste) are considered. The composites are fabricated and then subjected to high temperature solid particle erosion wear trials following Taguchi's L27 orthogonal array. The effects of different control factors on the erosion rate in an interactive environment are appraised by analysis of variance (ANOVA) which reveals the filler content as the most significant factor contributing 66.21%, followed by impact velocity (22.86%) and impingement angle (2.28%). A regression model based on the input–output parameters obtained from experimentation is constructed for prediction of erosion rate. Further, four predictive models using different machine learning algorithms are also proposed to predict the erosion rate of the composites. The feasibility and performance of each ML model is assessed using appropriate performance metrics. Among all the models, the gradient boosting machine model is found to be the most reliable model exhibiting the highest prediction accuracy and least errors.Highlights Development of novel class of composites reinforced with sponge iron slag. Database creation based on erosion wear experimentation on the composites. Data‐driven modeling for prediction of erosion rates using machine learning. Comparison of performance of different models and identifying the best one.

Prediction of erosive wear – A novel mathematical model

Several authors in past idealized erodent particles by assuming of spherical shapes. In reality, particles predominantly have irregular and angular shapes. The present study evolved a novel mechanistic mathematical model for prediction of solid particle erosive wear assuming the angular particles of square pyramidal shapes. The proposed model predicts the absolute volume loss as a cumulative contribution of deformation damage and cutting removal. It includes the effect of velocity, impingement angle, mass, abrasiveness factor of striking particles and the properties of target material. It can be effectively used for prediction of erosive wear for jet type of fluid flow.

Parametric analysis of erosion wear of sponge iron slag-filled ramie–epoxy composites using Taguchi and preference selection index methods

The present work reports on the development of a novel set of ramie–epoxy composites filled with sponge iron (SI) slag (0–30 wt.%) and on their response to solid particle erosion wear under different test conditions. SI slag is a by-product generated during the processing of SI to steel in arc or induction furnace. While these composites are fabricated using the conventional hand layup technique, the erosion tests are carried out using an air jet erosion tester following ASTM G76 test standard as per Taguchi's L27 orthogonal array. Mechanical characterization of ramie–epoxy composites suggests that the incorporation of SI slag improves their tensile strength by about 52%, flexural strength by 10% and micro-hardness by about 30%. A parametric appraisal of the erosion response carried out using Taguchi method reveals that the filler content, impact velocity and impingement angle are the most significant control factors influencing the erosion rate of these composites. The individual effects of different factors in wider ranges (impact velocity 25–125 m/s, filler content 0–30 wt.% and impingement angle 30–90°) are ascertained by conducting steady-state erosion experiments in controlled conditions. Preference selection index method, which is an effective multi-criteria decision-making tool is used to select the best candidate among all composites based on different physical, mechanical and wear test results. It is found that the composite with 30 wt.% SI slag content displays the optimal combination of properties. The worn morphologies of the eroded surfaces of the composites are studied and analyzed using electron microscopy to identify possible mechanisms causing the wear loss.

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

Erosion wear analysis of coconut shell dust filled epoxy composites using computational fluid dynamics and Taguchi method

This article depicts the solid particle erosion wear behavior of the coconut shell dust-filled epoxy composites. The erosion wear behavior of the composites is evaluated by a solid erosion test rig according to Taguchi’s design-of-experiment approach. The experiments are carried out by both sand and Al2O3 erodent. The study shows that the inclusion of coconut shell dust improves the erosion behavior of epoxy resin. The wear behavior analysis also reveals that erodent size, angle of impingement (B), and impact velocity (C) are the most significant factors in that sequence that influence the erosion rate of the composites. Further, computational fluid dynamics analysis (CFD) is implemented to study the temperature and velocity gradient of the composites under an erosive environment. The experimental results are validated with CFD simulation results, and both values are found to be in better agreement.

Solid Particle Erosion Wear Characteristics of WC-Reinforced Ni-Based Coating Deposited by Oxy-Acetylene Flame Welding

Solid Particle Erosion Wear Characteristics of WC-Reinforced Ni-Based Coating Deposited by Oxy-Acetylene Flame Welding

Electrochemical corrosion and solid particle erosion response of Y2O3 dispersed FeAl coatings deposited by detonation spray

The electrochemical corrosion and erosion wear behaviors of detonation sprayed ODS FeAl powder coatings on T91 substrate were investigated. Electrochemical corrosion resistance of the deposited coatings was evaluated in three different aqueous media, namely 3.5 wt% (0.61 M) NaCl, 2 N (1 M) H2SO4 and 3.5 wt% (0.25 M) Na2SO4 and are compared with T91 substrate and detonation sprayed Cr3C2–25NiCr coatings (on T91 substrate). The ODS FeAl coatings shown improved corrosion resistance in 3.5 wt% Na2SO4 than T91 substrate. However, the Cr3C2–25NiCr coatings have shown consistently better corrosion resistance than T91 substrate and ODS FeAl coatings in all the aqueous media. The corrosion mechanisms investigated imply that the higher corrosion rate of FeAl coatings as compared to the Cr3C2–25NiCr coatings is well compensated by the uniform corrosion in the case of former than the localized and intense corrosion in the case of later coatings and substrate material. In contrast, the solid particle erosion wear studies conducted at two different temperatures namely, room temperature (25 °C) and 400 °C have revealed that the ODS FeAl coatings exhibited 4 to 5 times improved wear resistance than that of Cr3C2–25NiCr coatings at room temperature and 1.5 to 2.5 times at a higher temperature (400 °C). Also, the ODS FeAl coatings have performed marginally better than the T91 substrate at both the test temperatures. The results obtained together with the observations made demonstrate a leap step towards the development of novel thermal spray grade feedstock materials as an alternative to industrially well-known Cr3C2–25NiCr coatings and open up a new avenue of techno-economic benefits that can be further explored.

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.

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.

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

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

Studies on structural, mechanical and erosive wear properties of ZA-27 alloy-based micro-nanocomposites

Metal matrix nanocomposites represent a relatively new class of material, which is still being extensively investigated. Most of the studies, however, are devoted to aluminium- or magnesium-based nanocomposites. A limited number of studies focus on zinc alloy base nanocomposites, with fewer still concentrating on zinc alloy base micro-nanocomposites. In addition, most of the tribological studies investigate adhesive or abrasive wear resistance, whereas studies of erosive wear resistance lag well behind. It was previously shown that the presence of nanoparticles in ZA-27 alloy-based nanocomposites led to a slight increase in erosive wear resistance. Upon discovering that, the aim became to produce micro-nanocomposites that would retain the positive effect of nanoparticles, while further elevating performance, by combining microparticles with nanoparticles. The ZA-27 alloy-based micro-nanocomposites were reinforced with 3 wt. % Al2O3 microparticles (particle size approx. 36 μm) and with four different amounts (0.3, 0.5, 0.7 and 1 wt. %) of Al2O3 nanoparticles (particle size 20–30 nm). Tested materials were produced by the compocasting process, with mechanical alloying pre-processing. Solid particle erosive wear testing, with particle impact angle of 90°, showed that all micro-nanocomposites had significantly increased wear resistance in comparison to the reference material.

Alternative System Design for High Temperature Solid Particle Erosion Wear Problem

In order to simulate the wear behavior of materials subjected to solid particle erosion due to high temperature as well as velocity effect in operating conditions such as power plants and jet engines, ASTM G76 standard is not sufficient and test rig compliant with ASTM G211-14 standard must be put forward. In this context, a test rig, alternative to existing systems where solid particle erosion wear experiments can be performed in compliance with high temperature (~ 700 °C) and particle impact velocity (~ 150 m/s) conditions, has been designed and produced. In order to ensure the widespread use of this test rig, a resistance wire system was used to reach high temperatures of the heating system by achieving a different design solution. In the setup of this design, the perfect gas equation, heating power and ohm laws are also used. In addition, the designs of specimen fixture and particle feeding system, which are the determining parameters in erosion wear tests, have been updated. With the produced test rig; solid particle erosion experiments were carried out using Inconel 718 test specimens at 600 °C temperature, ~ 97 m/s erosive particle impact velocity and three different erosive particle impact angles (30°, 60° and 90°). In the experiments, especially the change of temperature over time was confirmed by the data obtained from both the test rig and the specimens.

Solid particle erosive wear study of polymer composite materials for wind turbine applications

AbstractIn this study, erosion wear tests in composites materials (carbon fiber and fiberglass) were performed in order to understand their behavior for blades of wind turbine applications. The erosion tests were also made in coated composites materials with a polyester resin (gel coat), to compare the wear erosion resistance with uncoated materials. The experimental tests were carried out according to some parameters to the ASTM G76 standard. The specimens had a rectangular shape with dimensions of 25 × 18 mm and a thickness of 4 mm. The erosive particle used was obtained from sea sand. High impact angles were used, 75°, 85°, and 90° and the velocity particle was 12 m/s. The duration of each test was 6 min, removing the specimens every 2 min to measure the amount of mass loss. In order to identify the wear mechanisms, scanning electron microscopy was used. The results showed that fiberglass specimens had a higher mass loss at 90° impact angle. The best erosive wear performance was obtained in the uncoated carbon fiber specimens at 85° impact angle.

Studies on Dry Sliding Wear and Solid Particle Erosive Wear Behaviours of Natural Fibre Composite Developed from Water Hyacinth Aquatic Plant for Automotive Application

In this research, an attempt is made to investigate the abrasive and erosion wear resistance of aquatic waste plant water hyacinth converted fibre‐reinforced polymer composites. From a novel approach, the new fibre extraction machine is designed to extract the hyacinth fibre from the parent plant and reinforce it to the epoxy matrix material to produce a natural fibre composite for frictional applications. The extracted fibre is dried in the open sunlight area for 22 to 35 days to remove moisture and external dust particles. Then, different weight percentages (15, 20, 25, 30, and 35) of composite samples are produced with the help of the hot press compression moulding technique. Improved hyacinth composite tribology properties are tested by utilizing the pin on the disk machine. This setup included various processing parameters like load (10, 20, and 30 N), velocities (1, 2, and 3 m/s), speed (160, 320, and 479 rpm), and constant sliding distance condition, and the erosion setup also influences the essential parameters like impact angle (30, 45, and 60°), erodent velocity (1, 2.5, and 3.3 m/s), and discharge rate (28, 41, and 72 g/m). The factorial techniques are used to identify the important design factors. The final results represent the weight loss, volume loss, and erosion rate of hyacinth fibre composite. By utilizing the SEM (scanning electron microscope), the worn surface morphology of different weight percentages of hyacinth fibre samples are analysed. To upgrade the usage of hyacinth reinforced composites for different industrial applications, wear and erosion studies are conducted with different parameter conditions.

Erosion Resistance of CFRP Composite Materials with Different Fiber Weaves Exposed to Cryogenic Treatment

Carbon fiber–reinforced polymers (CFRPs) are often exposed to solid particle erosion wear due to small particles moving freely in the atmosphere or in the environment and their impact on aircraft bodies. In this study, fiber weaves of CFRP composite materials of the following types were produced: unidirectional (U), plain weave multidirectional (P), and twill 2 × 2 weave multidirectional (T). Tests that involved three different CFRP composite materials were conducted at room temperature with two groups (pure and exposed to cryogenic liquid nitrogen treatment), at two different fiber directions (0° and 45°), and at four different impingement angles (30°, 45°, 60°, and 90°). Subsequently, erosion wear rate values were calculated and erosion rate–impingement angle graphs were produced for each fiber direction to study the effect of the different environments. Scanning electron microscopy images of surface deformation were compared between the different experimental conditions.