Solid Particle Erosion Research Articles

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

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

Failure mechanisms of interfacial coatings (MCrAlY+8YSZ) on high temperature solid particle erosion

Failure mechanisms of interfacial coatings (MCrAlY+8YSZ) on high temperature solid particle erosion

Synthesis and coating properties of (La0.5Eu0.25Y0.25)2Zr2O7 ceramic powder

The (La0.5Eu0.25Y0.25)2Zr2O7 (LEYZ) ceramic powder for spraying was prepared and synthesised by combining spray granulation and solid phase reaction phase, and a double ceramic layer structure with (La0.5Eu0.25Y0.25)2Zr2O7 ceramic surface coating and YSZ intermediate coating was prepared by atmospheric plasma spraying. Experimental characterisation revealed that the moulding state of spray granulated powders was significantly influenced by the solid content. When the solid content is small, the viscosity of the slurry is insufficient, and the prepared powder has poor formability and small overall particle size. When the solid content is large, the slurry is too viscous, which easily leads to unfavourable conditions such as sticky walls. The best formability of the pelletised powder was obtained with a solid content of 55 wt-% and a binder content of 2.0 wt-%. Compared with La2Zr2O7 (LZ) ceramics, the fracture toughness of the rare-earth co-doped modified LEYZ ceramic coating was increased by 8.4% and the bond strength was increased by 49.9%, showing good toughness and crack resistance. Moreover, LEYZ coating has significantly better resistance to solid phase particle erosion than LZ coating, with 46.3% and 45.4% reduction in erosion rate at 45° and 90°, respectively.

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.

Investigations of Solid Particle Erosion on the Flow Channel Walls of a Radial Turbine for Diesel Engine Applications

Investigations of Solid Particle Erosion on the Flow Channel Walls of a Radial Turbine for Diesel Engine Applications

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 Effect of HVOF Spray Distance on Solid Particle Erosion Resistance of WC-based Cermets Bonded by Co, Co-Cr and Ni Deposited on Mg-alloy Substrate

The Effect of HVOF Spray Distance on Solid Particle Erosion Resistance of WC-based Cermets Bonded by Co, Co-Cr and Ni Deposited on Mg-alloy Substrate

Bioinspired and Multifunctional Tribological Materials for Sliding, Erosive, Machining, and Energy-Absorbing Conditions: A Review.

Friction, wear, and the consequent energy dissipation pose significant challenges in systems with moving components, spanning various domains, including nanoelectromechanical systems (NEMS/MEMS) and bio-MEMS (microrobots), hip prostheses (biomaterials), offshore wind and hydro turbines, space vehicles, solar mirrors for photovoltaics, triboelectric generators, etc. Nature-inspired bionic surfaces offer valuable examples of effective texturing strategies, encompassing various geometric and topological approaches tailored to mitigate frictional effects and related functionalities in various scenarios. By employing biomimetic surface modifications, for example, roughness tailoring, multifunctionality of the system can be generated to efficiently reduce friction and wear, enhance load-bearing capacity, improve self-adaptiveness in different environments, improve chemical interactions, facilitate biological interactions, etc. However, the full potential of bioinspired texturing remains untapped due to the limited mechanistic understanding of functional aspects in tribological/biotribological settings. The current review extends to surface engineering and provides a comprehensive and critical assessment of bioinspired texturing that exhibits sustainable synergy between tribology and biology. The successful evolving examples from nature for surface/tribological solutions that can efficiently solve complex tribological problems in both dry and lubricated contact situations are comprehensively discussed. The review encompasses four major wear conditions: sliding, solid-particle erosion, machining or cutting, and impact (energy absorbing). Furthermore, it explores how topographies and their design parameters can provide tailored responses (multifunctionality) under specified tribological conditions. Additionally, an interdisciplinary perspective on the future potential of bioinspired materials and structures with enhanced wear resistance is presented.

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.

Role of high-speed nanoindentation mapping to assess the structure-performance correlation of HVAF-sprayed Cr3C2-25NiCr coating

Cr3C2-NiCr coatings deposited by high-velocity air-fuel (HVAF) spray can potentially exhibit superior wear performance. However, the microstructural variations caused by altering HVAF process parameters and secondary heat treatment considerably impact coating characteristics and wear performance. The effective characterization of such microstructural variations at the micrometer length scale using conventional techniques is limited. In this study, we employ a high-speed nanoindentation mapping technique to spatially map the properties of HVAF sprayed Cr3C2-NiCr coating deposited by varying particle size-combustion mode combination, which was in the as-deposited as well as heat-treated state. Despite the significant microstructural heterogeneity at a small scale, the hardness maps show excellent correlation with the microstructure. The data extracted from the nanoindentation maps estimate the area fraction and average hardness of individual phases (carbide, binder, interacted region) in the coatings. Insights on the role of individual constituents on the coating microstructure and mechanical property evolution are presented. The hardness evolution of the individual constituents with processing conditions and secondary heat treatment is correlated with the solid particle erosion performance of the coatings. Overall, Cr3C2-NiCr coatings deposited through the correct choice of particle size-combustion mode combination and heat treatment improved the desired phase distribution, resulting in superior erosion resistance.

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%.

Erosion Analysis and Optimal Design of Sand Resistant Pipe Fittings

Erosion of solid particles in a pipe elbow containing a 90° angle is investigated by simulation methods. In the process of shale gas exploitation, the impact of solid particles carried by fluid on the inner surface wall of pipes, as well as the turbulent flow, cause the erosion of pipes, which brings about heavy economic losses for the oil and gas industry. In the impact erosion of the inner surface wall of the pipe, the worst erosion occurs at the elbow. In this study, the erosion of a pipe elbow which has been widely used in actual production is analyzed, and the influence of the fluid velocity, the solid particle size, and the wall roughness on the erosion is investigated. Additionally, the simulation results of the erosion with the rebound and freeze boundary conditions are compared, indicating that setting the freeze boundary condition could significantly improve the computational efficiency by 74% with the acceptable accuracy. In order to reduce the impact erosion in the pipe elbow containing a 90° angle, an optimal design is proposed that can reduce the maximum erosion rate by 52.4%. These results complement the research of elbow erosion and provide ideas for the optimization problem of a pipe elbow containing a 90° angle.

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°.

DEVELOPMENT OF A THEORETICAL MODEL TO ESTIMATE THE EROSION WEAR RATE OF POLYMER COMPOSITES

Nowadays Polymeric materials reinforced with synthetic fibers play an incredible role in almost all spheres of day-to-day life due to their elevated stiffness, outstanding strength-to-weight ratio, and electrical, thermal, and wear properties. The accumulation of micro-fillers or particulates in polymeric components reinforced with fibers made from synthetic materials may enhance their properties compared to fiber-reinforced composites. Solid particle erosion of engineering components made up of polymer composites is a major industrial problem, and it is significantly affected by the components' mechanical characteristics and their working environment. Therefore, it's essential to research the polymer composites' solid particle erosion properties. One area that has attracted less research attention is the impact of particle fillers and E-glass fiber reinforcing on erosion wear characteristics. Because of its significance to science and industry, research in this area is especially needed about particle fillers. Furthermore, to properly design a machine or structural component and use materials that will increase wear resistance, one must have a thorough grasp of how every system variable affects wear rate. In this research article, to estimate the erosion damage induced by solid particle impact on composites without conducting the experiment on an air jet erosion test rig, a theoretical model is proposed. The successful implementation of this theoretical model can reduce the experimentation cost with good quantitative accuracy.

Methods for increasing the cavitation and solid particle erosion resistance of 20GL and 30L steels based on their surface modification

The article presents the results of studies of cavitation and solid particle erosion resistance of samples of 20GL and 30L steels with various surface modification options based on nitriding and boriding processes. Tests for cavitation resistance were carried out according to the ASTM G134-17, and for solid particle erosion resistance - according to the ASTM G76-13. It was revealed that to increase wear resistance, the depth of modification of the considered steels should be at least 80 microns. Based on the totality of cavitation and solid particle erosion studies carried out, the best option for surface modification for 20GL steel is boriding, and for 30L steel nitriding.

A Numerical Comparison of 2D and 3D CFD Modelling for Contraction and Expansion Geometries with an Emphasis on Solid Particles Erosion

In this study, erosion patterns and magnitude are compared between the outputs of 2D and 3D CFD models in contraction and expansion geometries. ANSYS Fluent software was used to model a circular cross-section geometry with a contraction and the results were compared to published experimental data. The simulation findings showed that there is good agreement between the 2D and 3D CFD models and the experimental data in terms of fluid flow properties such as velocity profiles and magnitude. It also demonstrated that the 2D and 3D CFD models' representations of erosion patterns and magnitudes are equivalent. The 3D CFD simulations were able to provide more information than the 2D CFD simulations, particularly in terms of erosion distribution over the entire geometry.

Effects of Heat Treatment and Erosion Particle Size on Erosion Resistance of a Hypereutectic High-Chromium Cast Iron

This research addresses the erosive resistance of a hypereutectic high-chromium cast iron subjected to solid particle erosion. The study stems from a specific application of high-chromium cast iron, i.e., the critical surfaces of large industrial fans operating in a cement clinker grinding plant where such damage is a limiting factor for the components’ lifespan. A dedicated experimental investigation on the impact of substrate microstructure and erodent particle size on erosion resistance was set. The experimental campaign, conducted on a dedicated test bench per the ASTM G76 standard, comprised the analysis of the as-received, tempered, and destabilized conditions for the cast iron. From a preliminary image analysis of the microstructural features, two diameters of the erodent powder for the erosion tests were defined. The observed erosion rate decreased with the increase in the mean particle diameter of the erodent, indicating more severe erosive conditions for smaller particles. From the analysis of the worn surfaces, it was possible to highlight the involved mechanisms concerning the considered test combinations. For the as-received condition, the erosion rate with the larger mean particle diameter of the erodent decreased three times compared to the smaller one. For the heat-treated conditions, the erosion rate was halved with the larger mean particle diameter of the erodent. The proposed analysis, intended to acquire more insight into the limiting factor for the components’ lifespan for erosive wear damage, proved that erosion resistance is not dependent on the material’s hardness. The contribution of the mean particle diameter of the erodent is predominant compared to the substrate conditions.

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

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