Erosive Wear Study of PPLSF/Glass Fiber Reinforced Hybrid Laminates

This work is focused to examine the erosive performance of hybrid Palmyra palm leaf stalk fiber(PPLSF)/glass polyester laminate against solid particle bombardment.A hand lay-up method was adopted for the fabricating four piles of five distinct laminates with different stacking order glass and PPLSF layers.Amongst them,one group of pure PPLSF and pure E-glass laminates were fabricated.The hybrid laminates were exposed to high speed stream of solid sand particle at three distinct impact velocities(48,70 and 82 m/s)and four different angles of impingement(30°,45°,60°and 90°).The effect of particle velocity,angle of impingement and stacking order on both wear rate and efficiency were highlighted.The experimental assessment reveals a significant improvement in erosive wear resistance properties due to hybridization of PPLSF with E-glass.Again,the laminates with PPLSF layer as skin and glass as core layer exhibited better erosive wear resistance properties than other types of laminates.Further,a maximum value of erosion at lower velocity(48 m/s)is also noticed at 45°impingement angle.However,at high velocity of impact 70 m/s and 82 m/s,the maximum rate of erosion has been shifted from 45°impact angle to 60°impact angle.The alternation of this semi-ductile character to semi-brittle character is evidenced by analyzing the experimental data.Further to justify the mode of erosion,the eroded surface samples were inspected by scanning electron microscope(SEM).

Erosive Wear and Wear Mechanism of in situ TiC_P/Fe Composites

The base structure of in situ TiCp/Fe composites fabricated under industrial condition was changed by different heat treatments. Erosive wear tests were carried out and the results were compared with that of wear-resistant white cast iron. The results suggest that the wear resistance of the in situ TiCp/Fe composite is higher than that of wear-resistant white cast iron under the sand erosive wear condition. The wear mechanism of the wear-resistant white cast iron was a cycle process that base surface was worn and carbides were exposed, then carbides was broken and wear pits appeared. While the wear mechanism of in situ TiCp/Fe composite was a cycle process that base surface was worn and TiC grains were exposed and dropped. The wear resistance of in situ TiCp/Fe composite was lower than that of wear-resistant white cast iron under the slurry erosive wear condition. Under such circumstance, the material was not only undergone erosive wear but also electrochemistry erosion due to the contact with water in the medium. The wear behaviours can be a combination of two kinds of wear and the sand erosive wear is worse than slurry erosive wear.

Taguchi approach to influence of processing parameters on erosive wear behaviour of Al7034-T6 composites

Taguchi technique was used to predict the influence of processing parameters on the erosive wear behavior Al7034-T6composite reinforced with SiC and Al2O3particles in different mass fractions.These hybrid metal matrix composites(HMMCs)werefabricated by using a simple technique called stir casting technique.Scanning electron microscope(SEM)was used to study thesurface morphology of the composite and its evolution according to processing time.The design of experiment(DOE)based onTaguchi’s L16orthogonal array was used to identify various erosion trials.The most influencing parameter affecting the wear rate wasidentified.The results indicate that erosion wear rate of this hybrid composite is greatly influenced more by filler content and impactvelocity respectively compared to other factors.This also shows the significant wear resistance with the increase in the filler contentsof SiC and Al2O3particles,respectively.

Assessment of the Erosive Wear Kinetics of Epoxy Coatings Modified with Nanofillers

The paper presents results of investigation on the erosive wear kinetics of epoxy coatings modified with alumina or silica nanoparticles. Natural weathering caused a decrease of their erosive wear resistance. After a 3-year natural weathering, highest erosive wear resistance showed the epoxy coating modified with alumina nanoparticles.

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.

Erosion Wear Behaviour of Kenaf/Glass Hybrid Polymer Composites

The awareness amongst the researchers to develop an environment friendly sustainable material leads to explore new class of plant-based fiber for making composites. Hybridization of such plant-based fiber with inclusion of engineered fiber is one of the promising methods to not only enhanced the mechanical performance but also suppressed the drawbacks that associate with such plant-based fiber to some extent. A usual hand lay-up method was taken-up in this work to fabricate four layered of hybrid kenaf(K)/glass(G)polyester laminates with different stacking order such as KKKK,KGKG,KGGK,GKKG and GGGG. The erosive character of the laminates was examined under three distinct particle velocities(48m/s, 70m/s,82m/s)and four different impact angles(30°, 45°, 60°, 90°). All fabricated laminates exhibited a semiductile character at lower velocities(48m/s and70m/s)as peak wear rate was observed at45° impact angle. However,they showed a semi-brittle character at high velocity(82m/s)as maximum rate of erosion was noticed at60° impact angle. Again,the influence of stacking order of piles on erosion wear was also clearly noticed. Moreover,the semi-brittle/semi-ductile characterization was also evidenced in accordance to the range of erosion efficiencies. The micro-structures of worn surfaces were inspected thoroughly from the images of scanning electron microscope(SEM)to evident the mechanism of erosion.

Erosive wear properties of ZA-27 alloy-based nanocomposites: Influence of type, amount, and size of nanoparticle reinforcements

Metal matrix nanocomposites(MMnCs)comprise a metal matrix filled with nanosized reinforcements with physical and mechanical properties that are very different from those of the matrix.In ZA-27 alloy-based nanocomposites,the metal matrix provides ductility and toughness,while usually used ceramic reinforcements give high strength and hardness.Tested ZA-27 alloy-based nanocomposites,reinforced with different types(Si C and Al2O3),amounts(0.2 wt.%,0.3 wt.%,and 0.5 wt.%)and sizes(25 nm,50 nm,and 100 nm)of nanoparticles were produced through the compocasting process with mechanical alloying pre-processing(ball milling).It was previously shown that the presence of nanoparticles in ZA-27 alloy-based nanocomposites led to the formation of a finer structure in the nanocomposites matrix and an improvement in the basic mechanical properties(hardness and compressive yield strength)through the enhanced dislocation density strengthening mechanism.Solid particle erosive wear testing demonstrated that these improvements were followed with an increase in the erosive wear resistance of tested nanocomposites,as well.Additionally,by analyzing the influences of type,amount,and size of nanoparticles on the erosive wear resistance of nanocomposites,it was demonstrated that there is an optimal amount of nanoparticles,which in our case is 0.3 wt.%,and that the presence of SiC nanoparticles and smaller nanoparticles in nanocomposites had more beneficial influence on erosive wear resistance.

Erosion wear at the bend of pipe during tailings slurry transportation:Numerical study considering inlet velocity,particle size and bend angle

Pipeline hydraulic transport is a highly efficient and low energy-consumption method for transporting solids and is commonly used for tailing slurry transport in the mining industry.Erosion wear(EW)remains the main cause of failure in tailings slurry pipeline systems,particularly at bends.EW is a complex phenomenon influenced by numerous factors,but research in this area has been limited.This study performs numerical simulations of slurry transport at the bend by combining computational fluid dynamics and fluid particle tracking using a wear model.Based on the validation of the feasibility of the model,this work focuses on the effects of coupled inlet velocity(IV)ranging from 1.5 to 3.0 m·s^(-1),particle size(PS)ranging from 50 to 650μm,and bend angle(BA)ranging from 45°to 90°on EW at the bend in terms of particle kinetic energy and incidence angle.The results show that the maximum EW rate of the slurry at the bend increases exponentially with IV and PS and first increases and then decreases with the increase in BA with the inflection point at 60°within these parameter ranges.Further comprehensive analysis reveals that the sensitivity level of the three factors to the maximum EW rate is PS>IV>BA,and when IV is 3.0 m/s,PS is 650μm,and BA is 60°,the bend EW is the most severe,and the maximum EW rate is 5.68×10^(-6)kg·m^(-2)·s^(-1).In addition,When PS is below or equal to 450μm,the maximum EW position is mainly at the outlet of the bend.When PS is greater than 450μm,the maximum EW position shifts toward the center of the bend with the increase in BA.Therefore,EW at the bend can be reduced in practice by reducing IV as much as possible and using small particles.

Effect of laser shock processing on erosive resistance of 6061-T6 aluminum

Application of laser shock processing （LSP） on 6061-T6 aluminum was made in order to evaluate its response to the erosive wear by silica sand. Impact angles of 15° , 30° , 60° and 90° were tested, two particle speeds （37 and 58 m/s） and two LSP irradiation conditions were used. Erosion marks were characterized by 3D profilometry and SEM analysis was conducted to identify the erosion mechanisms for each tested angle. The results showed a maximum erosive wear at low impact angles （ductile type behavior）. Erosion strength and the erosion mechanisms were not affected by the application of LSP and they were attributed to the high strain rate of the erosion phenomena. A few differences encountered on the erosion plots were explained on the basis of the surface roughness left by the LSP process. The maximum mass loss and the maximum erosion penetration happened in different impact angles （15° and 30° , respectively）. Finally, a well-defined erosion mechanism transition was observed, from cutting action at low impact angle, to crater formation at 90° of incidence.

Study of the Wear and Corrosion Performance of Hard Coatings Applied by Different Processes on Low Carbon Steel

Most of materials used in applications that require high wear resistance also undergo corrosive action of the service environment. The damage caused by the combination of both processes on the materials leads to huge economic losses in industry. Hard coatings are widely used as engineering solution to increase the lifetime of components operating in conditions of wear combined with corrosion. Nowadays, the most versatile techniques for applying such coatings are welding and thermal spraying. This work evaluates and compares the properties of coatings obtained by thermal spraying and welding using selected feeding materials. The performance of the coatings in corrosion and erosive wear tests is discussed. From the erosion tests performed for impact angle of 90°, a similar performance for the thermally sprayed tungsten carbide coatings and the welded stainless steel coatings with higher input energy was observed. Welded samples presented the best performance in corrosion test.

A review of biomimetic research for erosion wear resistance

One of the reasons behind failed engineering surfaces and mechanical components is particle erosion wear;thus,to mitigate its happening,biomimetic engineering is the current state-of-the-art being applied.Hence,this paper reviews the literature and the development trends on erosive wear resistance that employ biomimetic methods as well as analyze the bio-inspired surface,the bio-inspired structure,the bio-based materials,the associated challenges,and the future trends.Furthermore,the feasibility of the multi-biological and perspective on the coupling biomimetic method for anti-erosion wear are studied.It is concluded that the design of anti-erosion materials or structures by the bio-inspired methods is of great significance in the development of engineering applications.

Numerical study on erosion behavior of sliding sleeve ball seat for hydraulic fracturing based on experimental data

The sleeve sealing ball seat is one of the important components in the multistage fracturing process of horizontal wells.The erosion and wear of the surface will decrease the sealing performance of the fracturing ball and the ball seat.This leads to pressure leakage during the fracturing process and fracturing failure.In this paper,combined with the actual ball seat materials and working conditions during the fracturing process,the erosion tests of ductile iron and tungsten carbide materials under different erosion speeds,angles,and mortar concentrations are carried out.Then the erosion test results were analyzed by mathematical fitting,and a set of erosion models suitable for sliding sleeve setting ball seat materials were innovatively established.For the first time,this paper combines the erosion model obtained from the experiment and the computational fluid dynamics(CFD)with Fluent software to simulate the erosion of the ball seat.Based on the simulation results,the morphology of the sliding sleeve seat ball after erosion is predicted.Through analysis of the test and simulation results,it is showed that the erosion rate of tungsten carbide material is lower and the wear resistance is better under the condition of small angle erosion.This research can offer a strong basis for fracturing site selection,surface treatment methods,and prediction of failure time of ball seats.

Influence and optimization of swirler parameters on elbow wear of deep coal fluidization pipeline transportation system

Elbow wear is a major threat to the multiphase pipeline transportation industry,which has a negative impact on the stable operation of the transportation system.In order to find the wear reduction methods of elbows in the fluidization pipeline transportation system for 2000-meter-deep coal resources,the swirler was installed upstream of the elbows,and wear simulations and tests of three kinds of elbows were carried out.The results showed that the maximum wear rate(MWR)of elbows increased and then decreased along the elbow angle.Due to the different directions of gravity,the heavy wear position(HWP)of the horizontal-vertical(H-V)elbow was in front of the vertical-horizontal(V-H)elbow.Because the downstream portion of the horizontal-horizontal(H-H)elbow was still a horizontal pipe,the HWP of the H-H elbow almost covered the whole elbow.The swirler placed upstream of the elbows could make the particles at the elbow move to the intrados of the elbows,resulting in less collision between the particles and the extrados of the elbows,thus reducing the wear of the elbows.The wear reduction effects of swirlers on three different elbows were favorably connected with the guide vane angle(GVA)and negatively correlated with the guide vane length(GVL),decreased first and then increased as the guide vane height(GVH)increased,and were little affected by the guide vane number(GVN)and the guide vane thickness(GVT).The mathematical models between the MWR of the elbows and guide vane parameters were established.By bench tests,the wear reduction effect of three kinds of elbows under the optimal guide vane parameters was 58.4%,76.9%,and 78.6%,respectively.The errors between the bench test results and the simulation results were around 10%.

Analysis on cavitation erosion resistance of isostatic graphite

Isostatic graphite materials with 8%porosity and 14%porosity were prepared by the cold isostatic pressing process.Cavitation erosion resistance of the isostatic graphite was evaluated through cavitation tests in an ultrasonic vibration system.The volume loss and erosion morphology of the isostatic graphite were adopted to investigate the cavitation erosion resistance of the isostatic graphite.The cavitation test results show that after ultrasonic vibration of 14 h,the volume loss of the isostatic graphite materials with 8%porosity and 14%porosity are 35%and 46%of the carbon graphite material,respectively.The isostatic graphite material with 8%porosity exhibits an outstanding capability to resist cavitation erosion damage,and the cavitation erosion resistance of the isostatic graphite enhances with the decrease in porosity.The damage mechanism of isostatic graphite is brittle fracture attributed to the shock wave and micro jet.The isostatic graphite with low porosity exhibits excellent cavitation erosion resistance due to its fine graphite particles,homogeneous structure and high degree of hardness.

RESEARCH ON EROSION OF SILICON CARBIDE CERAMIC BLADE

In this paper, three linds of silicon carbide ceramic materials are chosen to perform the tests of material erosive wear. The relationship of ambient parameters, abrasive property and target property is studied in these experiments. Some main factors affecting erosive wear rate are determined by analysis of testing results, step wise regression analysis is completed according to the nondimensional quantities obtained by dimensional analysis. Relative hardness (partide to target Hp/Ht and erosion factor (Hpd1/2/Kic) are put for-ward to evaluate erosion property.

Effects of Nano-Aluminium on The Combustion of A PolyNIMMO-Based Propellant

Propellants containing micro-aluminium particles have been shown to produce faster burn rates than conventional gun propellants.However,they are also more abrasive than conventional propellants.Nano-material propellants have been reported to give similar benefits to micron-material propellants but without the disadvantage of increased abrasion.Tests were conducted to compare the burn rates,ignitability and wear rates of a propellant loaded with 0% aluminium,15% micro-aluminium and 15%nano-aluminium.Closed vessel tests showed a burn rate increase of 39% in the range 30-250 MPa,and 70% at low pressure(50-100MPa)for the nano-aluminium propellant compared with the baseline propellant.The micro-aluminium propellant showed only a 10%increase in the burn rate compared with the standard propellant.The ignition delay for the nano-aluminium propellant was slightly shorter than that of the baseline propellant.Substantially increased wear rates were measured for the micro-aluminium propellant.The nano-aluminium propellant showed reduced wear rates compared with the micro-aluminium propellant but these were still substantially greater than those for the baseline propellant.

STUDIES OF SOLID－LIQUID TWO－PHASE TURBULENT FLOWS AND WEAR IN HYDRAULIC TURBOMACHINERY

The Lagrangian equation of motion for solid particles in an arbitrary flow field is derived. The linear differential equation form and the general solution of this equation are obtained. Motion of solid particles in dilute solid-liquid turbulent flows is numerically solved and analysed. The K-εtwo-equation turbulence model, the volume fraction turbulence model, the mixed Eulerian-Lagrangian turbulence model, and the dense mixture turbulence model as well as the erosive wear model are developed. Using these models, the turbulent flows and the erosive wear in some hydraulic turbomachinery ducts are numerically predicted. The numerical results show good agreement with the experiments.

The hydro-abrasive erosion wear behavior of duplex-treated surfaces of AISI H13 tool steel

The influence of duplex surface treatments consisting of a DC-pulsed plasma nitriding process and subsequent coatings of CrN and TiAlN deposited by physical vapor deposition(PVD)on AISI H13 tool steel was studied in this article.The treated samples were characterized using metallographic techniques,SEM,EDS,and microhardness methods.Hydro-abrasive erosion wear tests were performed in a specifically designed wear tester in which the samples were rotated in a wear tank containing a mixture of distilled water and ceramic abrasive chips with a fixed rotational speed.The wear rates caused by the abrasive particle impacts were assessed based on accumulated weight loss measurements.The worn surfaces were also characterized using optical microscopy,SEM,and EDS.Microhardness measurements indicated a significant increase in the surface hardness of the duplex-treated samples.The surfaces of the samples with the TiAlN coating were approximately 15 times harder than that of the untreated samples and 3 times that of the plasma nitrided samples.Hydro-abrasive erosion wear results showed that the duplex surface treatments,especially the CrN coating,displayed the highest erosion wear resistance.

An erosion model for the discrete element method

A shear impact energy model （SIEM） of erosion suitable for both dilute and dense particle flows is pro- posed based on the shear impact energy of particles in discrete element method （DEM） simulations. A number of DEM simulations are performed to determine the relationship between the shear impact energy predicted by the DEM model and the theoretical erosion energy. Simulation results show that nearly one-quarter of the shear impact energy will be converted to erosion during an impingement. According to the ratio of the shear impact energy to the erosion energy, it is feasible to predict erosion from the shear impact energy, which can be accumulated at each time step for each impingement during the DEM simulation. The total erosion of the target surface can be obtained by summing the volume of material removed from each impingement. The proposed erosion model is validated against experiment and results show that the SIEM combined with DEM accurately predicts abrasive erosions.