Effect of Impact Angle on Erosive Abrasive Wear of Ductile and Brittle Materials

Authors: Ergin Kosa, Ali Göksenli

Abstract:

Erosion and abrasion are wear mechanisms reducing the lifetime of machine elements like valves, pump and pipe systems. Both wear mechanisms are acting at the same time, causing a “Synergy” effect, which leads to a rapid damage of the surface. Different parameters are effective on erosive abrasive wear rate. In this study effect of particle impact angle on wear rate and wear mechanism of ductile and brittle materials was investigated. A new slurry pot was designed for experimental investigation. As abrasive particle, silica sand was used. Particle size was ranking between 200- 500 μm. All tests were carried out in a sand-water mixture of 20% concentration for four hours. Impact velocities of the particles were 4.76 m/s. As ductile material steel St 37 with Vickers Hardness Number (VHN) of 245 and quenched St 37 with 510 VHN was used as brittle material. After wear tests, morphology of the eroded surfaces were investigated for better understanding of the wear mechanisms acting at different impact angles by using Scanning Electron Microscope. The results indicated that wear rate of ductile material was higher than brittle material. Maximum wear rate was observed by ductile material at a particle impact angle of 300 and decreased further by an increase in attack angle. Maximum wear rate by brittle materials was by impact angle of 450 and decreased further up to 900. Ploughing was the dominant wear mechanism by ductile material. Microcracks on the surface were detected by ductile materials, which are nucleation centers for crater formation. Number of craters decreased and depth of craters increased by ductile materials by attack angle higher than 300. Deformation wear mechanism was observed by brittle materials. Number and depth of pits decreased by brittle materials by impact angles higher than 450. At the end it is concluded that wear rate could not be directly related to impact angle of particles due to the different reaction of ductile and brittle materials.

Keywords: Erosive wear, particle impact angle, silica sand, wear rate, ductile-brittle material.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1108931

References:

[1] I. Finnie, “Erosion of surfaces by solid particles,” Wear, vol. 3, 1960, pp. 87-103.
[2] I. Finnie, “Some observations on the erosion of ductile metals,” Wear, vol. 19, 1972, pp. 81-90.
[3] J.G.A. Bitter, “A study of erosion phenomena—Parts I,” Wear, vol. 6, 1963, pp. 5-21.
[4] J.G.A. Bitter, “A study of erosion phenomena—Parts II,” Wear, vol. 6, 1963, pp. 169-190.
[5] M. Dorfman, “Wear-Resistant Thermal Spray Coatings”, Sulzer Technical Review, vol. 2, 2002, pp. 14-17.
[6] W. Tabakoff, “Erosion resistance of superalloys and different coatings exposed to particulate flows at high temperature,” Surface and Coatings Technology, vol. 120–121, 1999pp. 542–547.
[7] M. Adamiak, “Effect of Abrasive Size on Wear, Abrasion Resistance of Materials”, InTech, 2012, pp. 167-184.
[8] C. Katsich, E. Badisch, Manish Roy, G.R. Heath, and F. Franek, “Erosive wear of hardfaced Fe–Cr–C alloys at elevated temperature,” Wear, vol. 267, 2009, pp. 1856–1864.
[9] A. K. Jha, R. Batham, M. Ahmed, A. K. Majumder, O. P. Modi, S. Chaturved, and A. K. Gupta, “Effect of impinging angle and rotating speed on erosion behavior of aluminum”, Trans. Nonferrous Met. Soc. China, vol. 21, 2011, 32-38.
[10] D. Lopez, J.P. Congote, J.R. Can, A. Toro, and A.P. Tschiptschin, “Effect of particle velocity and impact angle on the corrosion–erosion of AISI 304 and AISI 420 stainless steels,” Wear, vol. 259, 2005, pp. 118- 124.
[11] P. Doubek, and J. Filipek, “Abrasive and erosive wear of technical materials,” Acta Univ. Agric. et Silvic. Mendel. Brun., vol. 3, 2011, pp. 13–22.
[12] P. Kulu, R. Tarbe, and A. Vallikivi, “Abrasive Wear of Powder Materials and Coatings,” Materials Science (Medziagotyra). vol. 11, 2005, pp. 230-234.
[13] I. Fort, “On hydraulic efficiency of pitched blade impellers,” Chemical Engineering Research and Design, vol.8-9, 2011, pp. 611–615.
[14] M.S. Patil, E. R. Deore, R. S. Jahagirdar, and S. V Patil, “Study of the Parameters Affecting Erosion Wear of Ductile Material in Solid-Liquid Mixture,” in Proc. of the World Congress on Engineering 2011, London, UK, 2011.
[15] F. Franek, E. Badisch, and M. Kirchgassner, “Advanced Methods for Characterisation of Abrasion/Erosion Resistance of Wear Protection Materials,” FME Transactions, vol. 37, 2009, pp. 61-70.
[16] S.A. Romo, J.F. Santa, and J.E. Giraldo, A. Toro, “Cavitation and highvelocity slurry erosion resistance of welded Stellite 6 alloy,” Tribology International, vol. 47, 2012, pp. 16–24.
[17] L. Fuyan, and S. Hesheng, “The effect of impingement angle on slurry erosion,” Wear, vol. 141, 1991, pp. 279-289.
[18] J.H. Neilson, and A. Gilchrist, “Erosion by a stream of solid particles,” Wear, vol. 11, 1968, pp. 111–122.
[19] G. R. Desale, B. K. Gandhi, and S.C. Jain, “Improvement in the design of a pot tester to simulate erosion wear due to solid–liquid mixture,” Wear, vol. 259, 2005, pp. 196-202.
[20] G. R. Desale, B. K. Gandhi, and S.C. Jain, “Effect of erodent properties on erosion wear of ductile type materials,” Wear, vol. 261, 2006, pp. 914-921.
[21] H. McI. Clark, and K. K. Wong, “Impact angle, particle energy and mass loss in erosion by dilute slurries,” Wear, vols.186-187, 1995, pp. 454- 464.
[22] I. Finnie, J. Wolak and Y. Kabil, Erosion of metals by solid particles, J. of Materials, vol. 2, 1967, pp. 682-700.
[23] A. Levy, Solid Particle Erosion and Erosion-corrosion of Materials, ASM International, 1997.
[24] A.J. van Riemsdijk and J.G.A. Bitter, “Erosion in gas-solid systems”, 5th World Petroleum Congress, New York, 1959, pp. 43-57.
[25] T. Hejwowski, “Erosive and abrasive wear resistance of overlay coatings,” Vacuum, vol. 83, 2009, pp. 166–170.
[26] Y.I. Oka, H. Olmogi, T. Hosokawa, M. Matsumura, “The impact angle dependence of erosion damage caused by solid particle impact,” Wear, vol. 203-204, 1997, pp. 573–579.
[27] H.McI. Clark, R. B. Hartwich, “A re-examination of the ‘particle size effect’ in slurry erosion”, Wear, vol. 248, 2001, pp. 147–161.