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Research Papers: Friction & Wear

Development of Correlations for Predicting the Slurry Erosion of Ductile Materials

[+] Author and Article Information
Girish R. Desale

Design Drawing and Workshop Engineering Department, C.S.M.C.R.I. Bhavnagar-364 002, India

Bhupendra K. Gandhi, S. C. Jain

Department of Mechanical & Industrial Engineering, Indian Institute of Technology, Roorkee- 247 667, India

J. Tribol 133(3), 031603 (Jul 25, 2011) (10 pages) doi:10.1115/1.4004342 History: Received July 11, 2010; Accepted June 06, 2011; Published July 25, 2011; Online July 25, 2011

Material loss due to erosion is a serious problem associated with the flow of solid-liquid mixtures. In the present work, erosion wear tests have been carried out in a slurry pot tester for seven different ductile type materials namely aluminum alloy (AA6063), copper, brass, mild steel, AISI 304L stainless steel, AISI 316L stainless steel, and turbine blade grade steel using three different erodents namely, quartz, alumina, and silicon carbide. Experiments have been performed at different orientation angles of target material at the velocities of 3, 6, and 8.33 m/s for solid concentrations of 10%, 20%, and 30% (by weight) and particle sizes of 363, 550, and 655 μm. The contribution of cutting wear in the total wear of ductile material at various orientation angles has been determined. It is observed that the maximum cutting wear angle for the ductile material depends on its hardness and a correlation is developed for its prediction. Also a methodology is proposed for estimation of the total erosion wear rate as a contribution of cutting and deformation wear rates. It is seen that this procedure results in an error of ±18% in estimation of erosion wear rate for the present experimental data.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Schematic diagram of slurry pot tester. (a) Assembly of slurry pot tester. (b) Fixing of wear specimen. (c) Angular plate. (d) Impingement angle.

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Figure 2

SEM micrographs of erodents

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Figure 3

Variation of erosion rate with orientation angle for various ductile materials using different particulate mixtures (d = 550 μm, Cw = 10%, and V = 3 m/s). (a) For aluminum alloy 6063. (b) For copper. (c) For brass. (d) For mild steel. (e) For AISI 304L steel. (f) For AISI 316L steel and AISI 403 steel using only quartz particulate slurry.

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Figure 4

Variation of cutting and deformation wear with orientation angle (d = 550 μm, Cw = 10%, and V = 3 m/s). (a) AA6063. (b) Copper. (c) Brass. (d) Mild steel. (e) AISI 304L steel. (f) AISI 316L and AISI 403 steels using quartz particulate slurry.

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Figure 5

Effect of target material hardness on maximum cutting wear and corresponding angle

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Figure 6

Accuracy of the correlation for angle for the maximum cutting wear

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Figure 7

Variation of normalized cutting wear with orientation angle

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Figure 8

Normalized cutting wear rate versus normalized angle. (a) For angle lower than the angle for maximum cutting wear. (b) For angle higher than angle for maximum cutting wear.

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Figure 9

Variation of Ec/f (α) with target material surface hardness (HT )

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Figure 10

Variation of Ec/f(α) (HT )−0.72 with modified shape factor of the erodent

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Figure 11

Variation of Ec/ [f (α) (HT )−0.72 (MSF)−0.80 ] with velocity of impacting solid particle

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Figure 12

Variation of Ec/[f(α) (HT )−0.72 (MSF)−0.80 (V)2.35 ] with solid concentration

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Figure 13

Variation of Ec/[f (α) (HT )−0.72 (MSF)−0.80 (V)2.35 (Cw)−0.11 ] with particle size

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Figure 14

Comparison of predicted and measured values of the erosion wear. (a) Velocity below 6 m/s. (b) Velocity higher than 6 m/s.

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