Solid Particle Erosion of AISI 304 SS Caused by Alumina Particles

This research work was carried out with the aim of continuing to expand knowledge on the behaviour of AISI 304 stainless steel against solid particle erosion. In this particular case, the steel was subjected to the impact of alumina particles, which are hard abrasives with irregular and angular shapes. Different characterization techniques were applied to gain a better understanding of alumina. For instance, particle size distribution was obtained using the Analysette 28 Image Sizer and the particle size was between 300 - 400 µm. SEM and EDS analysis were used to know the morphology and chemical composition of both the abrasive particles and AISI 304 stainless steel. Additionally, mechanical properties values such as the hardness and Young’s modulus of AISI 304 steel were attained using a Berkovich indenter (model TTX-NHT, CSM Instruments). On the other hand, two tests were carried out for each impact angle used, 30˚, 45˚, 60˚ and 90˚, with a particle velocity of 24 ± 2 m/s and an abrasive flow rate of 63 ± 0.5 g/min, employing a test rig based on ASTM G76-95 standard. SEM images using two detectors, Backscattered Electron Detector (BED) and Low Electron Detector (LED), were employed to identify the wear mechanisms on the AISI 304 eroded surfaces at 30˚ and 90˚. Finally, the erosion rates of AISI 304 compared to those results reached by AISI 1018 steel and AISI 420 stainless steel tested under identical conditions in previous works.

Particle erosion of C/C-SiC composites with different Al addition in reactive melt infiltrated Si

Particle erosion of C/C-SiC composites prepared by reactive melt infiltration with different Al addition was studied by gas-entrained solid particle impingement test.SEM,EDS and XRD were performed to analyze the composites before and after erosion.The results indicate that a U shape relationship curve presents between the erosion rates and Al content,and the lowest erosion rate occurs at 40 wt%Al.Except for the important influence of compactness,the increasing soft Al mixed with reactive SiC,namely the mixture located between carbon and residual Si also,plays a key role in the erosion of the C/C-SiC composites through crack deflection,plastic deformation and bonding cracked Si.

Progress in Bio‑inspired Anti‑solid Particle Erosion Materials:Learning from Nature but Going beyond Nature

Solid particle erosion is a common phenomenon in engineering fields,such as manufacturing,energy,military and aviation.However,with the rising industrial requirements,the development of anti-solid particle erosion materials remains a great challenge.After billions of years of evolution,several natural materials exhibit unique and exceptional solid particle erosion resistance.These materials achieved the same excellent solid particle erosion resistance performance through diversified strategies.This resistance arises from their micro/nanoscale surface structure and interface material properties,which provide inspiration for novel multiple solutions to solid particle erosion.Here,this review first summarizes the recent significant process in the research of natural anti-solid particle erosion materials and their general design principles.According to these principles,several erosion-resistant structures are available.Combined with advanced micro/nanomanufacturing technologies,several artificial anti-solid particle erosion materials have been obtained.Then,the potential applications of anti-solid particle erosion materials are prospected.Finally,the remaining challenges and promising breakthroughs regarding anti-solid particle erosion materials are briefly discussed.

Particle erosion of infrared materials

Erosion test of some infrared （IR） optical crystals （Ge, ZnS, MgF2, and quartz） was conducted with a number of different erodents （glass bead, and angular SiC, SiO2, Al2O3） by a homemade gas-blasting erosion tester. The influence of impact angle, impact velocity, erodent, and erosion time on the erosion rate and the effect of erosion on their IR transmittance were studied. The dam- aged surface morphology was characterized by scanning electron microscopy, and the erosion mechanism was explored. All of the materials show the maximum in wear versus impact angle at 90°, confirming their brittle failure behavior. It is found that the erosion rate is dependent on the erodent velocity by a power law, and it is highly correlated to the hardness of the erodent. The erosion rate-time curves do not show an incubation state, but an accelerated erosion period followed a maximum erosion （steady state）. The decrease of IR transmittance is direct proportion to the erosion rate. Although the material loss occurs primarily by brittle process, ductile behavior is clearly an important feature, especially for MgF2 and ZnS.

Flow field analysis and particle erosion of tunnel-slope systems under coupling between runoff and fast (slow) seepage

The presence of particles on the surface of a tunnel slope renders it susceptible to erosion by waterflow,which is a major cause of soil and water loss.In this study,a nonlinear mathematical model and a mechanical equilibrium model are developed to investigate the distribution offlowfields and particle motion characteristics of tunnel slopes,respectively.The mathematical model offlowfields comprises three parts:a runoff region,a highly permeable soil layer,and a weakly permeable soil layer.The Navier‒Stokes equation controlsfluid motion in the runoff region,while the Brinkman-extended Darcy equation governs fast and slow seepage in the highly and weakly permeable soil layers,respectively.Analytical solutions are derived for the velocity profile and shear stress expression of the modelflowfield under the boundary condition of continuous transition of velocity and stress at thefluid‒solid interface.The shear stress distribution shows that the shear stress at the tunnel-slope surface is the largest,followed by the shear stress of the soil interface,indicating that particles in these two locations are most vulnerable to erosion.A mechanical equilibrium model of sliding and rolling of single particles is established at thefluid‒solid interface,and the safety factor of particle motion(sliding and rolling)is derived.Sensitivity analysis shows that by increasing the runoff depth,slope angle,and soil permeability,the erosion of soil particles will be aggravated on the tunnel-slope surface,but by increasing the particle diameter,particle-specific gravity,and particle stacking angle,the erosion resistance ability of the tunnel-slope surface particles will be enhanced.This study can serve as a reference for the analysis of surface soil and water loss in tunnel-slope systems.

Particle Erosion Resistance of Bionic Samples Inspired from Skin Structure of Desert Lizard, Laudakin stoliczkana

In order to improve the particle erosion resistance of engineering surfaces, this paper proposed a bionic sample which is inspired from the skin structure of desert lizard, Laudakin stoliczkana. The bionic sample consists of a hard shell （aluminum） and a soft core （silicone rubber） which form a two-layer composite structure. The sand blast tests indicated that the bionic sample has better particle erosion resistance. In steady erosion period, the weight loss per unit time of the bionic sample is about 10% smaller than the contrast sample. The anti-erosion mechanism of the bionic sample was studied by single particle impact test. The results show that, after the impact, the kinetic energy of the particle is reduced by 56.5% on the bionic sample which is higher than that on the contrast sample （31.2%）. That means the bionic sample can partly convert the kinetic energy of the particle into the deformation energy of the silicone rubber layer, thus the erosion is reduced.

Impact of inter-particle collision on elbow erosion based on DSMC-CFD method

In this work,computational fuid dynamics(CFD)is used to study elbow erosion due to a gas-solid two-phase fow.In particular,the direct simulation Monte Carlo(DSMC)method is used to study the impact of inter-particle collision on the erosion behavior.The two-way coupled Euler-Lagrange method is used to solve the gas-solid fow,and the DSMC method is used to consider the collision behavior between particles.The efects of key factors,such as the particle concentration distribution and inter-particle collision,on the erosion ratio are evaluated and discussed.The efectiveness of the method is verifed from experimental data.The results show that the inter-particle collision signifcantly infuences the particle movement path and erosion ratio.When the inter-particle collision is considered,the maximum erosion position is ofset.The erosion model proposed by Oka et al.,who used the DSMC method,agrees best with the experimental data,and the average percentage error decreases from 39.2 to 27.4%.

Experimental Investigation on Combustion Performance of Solid Propellant Subjected to Erosion of Particles with Different Concentrations

A test device with rectangular channel is developed to study the combustion performance of solid propellant in high temperature particles erosion.The flowfields in this newdevice and a test device with circular channels are simulated numerically.The particle erosion experiments in these two devices are carried out under different particle concentrations.The results showthat the test device with rectangular channel can effectively improve the clarity and precision of combustion diagnosis image and can be used for research on combustion performance of solid propellant under lowconcentration particle erosion;the circular channel device has good particle convergent effect,provides high concentration particle erosion,and can be used for research on the combustion performance of solid propellant under high concentration particle erosion.The experiment data indicates that the propellant burning rate does not change obviously in lower particle concentration;the propellant with lower static burning rate increases remarkably under particle erosion,while the propellant with high static burning rate is not sensitive to the particle erosion.

Al-modification for PS-PVD 7YSZ TBCs to improve particle erosion and thermal cycle performances

Plasma spray-physical vapor deposition(PS-PVD)as a novel process was used to prepare feather-like columnar thermal barrier coatings(TBCs).This special microstructure shows good strain tolerance and non-line-of-sight(NLOS)deposition,giving great potential application in aero-engine.However,due to serious service environment of aero-engine,particle erosion performance is a weakness for PS-PVD 7YSZ TBCs.As a solution,an Al-modification approach was proposed in this investigation.Through in-situ reaction of Al and ZrO2,anα-Al2O3 overlay can be formed on the surface of 7YSZ columnar coating.The results demonstrate that this approach can improve particle erosion resistance since hardness improvement of Al-modified TBCs.Meanwhile,as another important performance of thermal cycle,it has a better optimization with 350-cycle water-quenching,compared with the as-sprayed TBCs.

Deep bed filtration model for cake filtration and erosion

Many phenomena in nature and technology are associated with the filtration of suspensions and colloids in porous media. Two main types of particle deposition,namely, cake filtration at the inlet and deep bed filtration throughout the entire porous medium, are studied by different models. A unified approach for the transport and deposition of particles based on the deep bed filtration model is proposed. A variable suspension flow rate, proportional to the number of free pores at the inlet of the porous medium, is considered. To model cake filtration, this flow rate is introduced into the mass balance equation of deep bed filtration. For the cake filtration without deposit erosion,the suspension flow rate decreases to zero, and the suspension does not penetrate deep into the porous medium. In the case of the cake filtration with erosion, the suspension flow rate is nonzero, and the deposit is distributed throughout the entire porous medium. An exact solution is obtained for a constant filtration function. The method of characteristics is used to construct the asymptotics of the concentration front of suspended and retained particles for a filtration function in a general form. Explicit formulae are obtained for a linear filtration function. The properties of these solutions are studied in detail.

An experimental study on the influences of wind erosion on water erosion

In semi-arid regions, complex erosion resulted from a combination of wind and water actions has led to a massive soil loss and a comprehensive understanding of its mechanism is the first step toward prevention of the erosion. However, the mutual influences between wind erosion and water erosion have not been fully understood. This research used a wind tunnel and two rainfall simulators and simulated two rounds of alternations between wind erosion and water erosion（i.e., 1^（st） wind erosion–1^（st） water erosion and 2^（nd） wind erosion–2^（nd） water erosion） on three slopes（5°, 10°, and 15°） with six wind speeds（0, 9, 11, 13, 15, and 20 m/s） and five rainfall intensities（0, 30, 45, 60, and 75 mm/h）. The objective was to analyze the influences of wind erosion on succeeding water erosion. Results showed that the effects of wind erosion on water erosion were not the same in the two rounds of tests. In the 1^（st） round of tests, wind erosion first restrained and then intensified water erosion mostly because the blocking effect of wind-sculpted micro-topography on surface flow was weakened with the increase in slope. In the 2^（nd） round of tests, wind erosion intensified water erosion on beds with no rills at gentle slopes and low rainfall intensities or with large-size rills at steep slopes and high rainfall intensities. Wind erosion restrained water erosion on beds with small rills at moderate slopes and moderate rainfall intensities. The effects were mainly related to the fine grain layer, rills and slope of the original bed in the 2^（nd） round of tests. The findings can deepen our understanding of complex erosion resulted from a combination of wind and water actions and provide scientific references to regional soil and water conservation.

Numerical analysis of submarine landslides using a smoothed particle hydrodynamics depth integral model

Submarine landslides can cause severe damage to marine engineering structures. Their sliding velocity and runout distance are two major parameters for quantifying and analyzing the risk of submarine landslides.Currently, commercial calculation programs such as BING have limitations in simulating underwater soil movements. All of these processes can be consistently simulated through a smoothed particle hydrodynamics（SPH） depth integrated model. The basis of the model is a control equation that was developed to take into account the effects of soil consolidation and erosion. In this work, the frictional rheological mode has been used to perform a simulation study of submarine landslides. Time-history curves of the sliding body＇s velocity, height,and length under various conditions of water depth, slope gradient, contact friction coefficient, and erosion rate are compared; the maximum sliding distance and velocity are calculated; and patterns of variation are discussed.The findings of this study can provide a reference for disaster warnings and pipeline route selection.

Erosion wear experiments and simulation analysis on bionic anti-erosion sample

The dorsal surface of a desert lizard has excellent particle erosion resistance.In this paper,a bio-inspired sample was designed and fabricated based on the biological characteristics of the dorsal skin of the desert lizard(Laudakin stoliczkana).The bionic sample consists of two materials with different characteristics,which form a two-layer composite structure.The particle erosion property and erosion wear mechanism of the bionic sample was studied by means of sandblast experiment and numerical simulation,respectively.The experimental results show that,in the stage with steady abrasion rate,the weight loss per unit time of the bionic sample is about 10%lesser than the control sample.The numerical simulation indicated that the two-layer structure of the bionic sample can efficiently absorb the normal stress,and dissipate the stress in the horizontal direction.Thus,the stress concentration on the sample surface is suppressed.The two-layer structure is contributed to the decentralizing of the stress distribution,and thus the occurrence probability of erosion damage can be decreased.

Numerical study of gas-solid two-phase flow and erosion in a cavity with a slope

Gate valve is mainly used to turn on or turn off the pipeline in pneumatic conveying.When the gate valve is fully open,the particles are easy to collide with the cavity rear wall and enter into the cavity,resulting in particles’accumulation in the cavity.The particles in cavity will accumulate between the cavity bottom and the flashboard bottom wall and prevent the gate from turning off normally.Meanwhile,the particles’collision with cavity rear wall will cause serious erosion.Both the particles’accumulation and erosion will cause the poor sealing of the gate valve,further resulting in the leakage of the pipeline system.To reduce the particles’accumulation in cavity and erosion on cavity when the gate valve is fully open,we simplify the gate valve into a cavity structure and study it.We find that adding a slope upstream the cavity can effectively reduce the particles’accumulation in the cavity and the erosion on the cavity rear wall.In this work,Eulerian-Lagrangian method in commercial code(FLUENT)was used to study the gas-solid two-phase flow and erosion characteristics of a cavity with a slope.The particle distribution shows that the particles with Stokes number St=1.3 and St=13 cannot enter the cavity due to the slope,but the particles with St=0.13 enter the cavity following the gas.For St=13,the particles collide with the wall many times in the ideal cavity.Erosion results show that the slope can transfer the erosion on cavity rear wall to the slope and reduce the maximum erosion rate of the wall near the cavity to some degrees.

Design optimization of guide vane for mitigating elbow erosion using computational fluid dynamics and response surface methodology

A90°elbow equipped with guide vanes was developed with the intent of reducing elbow erosion.Numerical models were formed to predict the maximum erosion rate of elbow and Face-1,and the response surface methodology was used to study the relationship between the erosion rate and structural parameters of guide vane.A second-order response surface model was established to determine the relationship between R and variables,and a reduced cubic(RC)polynomial model was obtained to reveal the relation-ship between R2 and the three factors.The numerical results show that the low-speed region is expended and the maximum discrete particle matter(DPM)concentration is reduced after installing the guide vane.This internal component provides a shelter for the elbow from the direct impact of high-speed solids.