Research Papers: Applications

A Study on Slurry Erosion Behavior of High Chromium White Cast Iron

[+] Author and Article Information
M. A. Al-Bukhaiti

Mechanical Engineering Department,
Faculty of Engineering,
Sana'a University,
Sana'a 1438, Yemen
e-mail: m.albukhaiti@gmail.com

A. Abouel-Kasem

Mechanical Engineering Department,
Faculty of Engineering,
King Abdulaziz University,
P. O. Box 344,
Rabigh 21911, Kingdom of Saudi Arabia
e-mail: aaahmed2@kau.edu.sa

K. M. Emara

Mechanical Engineering Department,
Faculty of Engineering,
Assiut University,
Assiut 71516, Egypt
e-mail: k.emara45@yahoo.com

S. M. Ahmed

Mechanical Engineering Department,
Faculty of Engineering,
Assiut University,
Assiut 71516, Egypt
e-mail: shemy2007@yahoo.com

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received December 7, 2015; final manuscript received November 24, 2016; published online March 29, 2017. Assoc. Editor: Robert L. Jackson.

J. Tribol 139(4), 041102 (Mar 29, 2017) (7 pages) Paper No: TRIB-15-1439; doi: 10.1115/1.4035346 History: Received December 07, 2015; Revised November 24, 2016

High chromium white irons (HCCIs) are used extensively throughout the mineral processing industry to handle erosive and corrosive slurries. This study is an investigation of the effect of impact angle and velocity on slurry erosion of HCCI. The tests were carried out using a rotating whirling-arm rig with particle concentration of 1 wt. %. Silica sand which has a nominal size range of 500–710 μm was used as an erodent. The results were obtained for angles of 30 deg, 45 deg, 60 deg, and 90 deg to the exposed surface and velocities of 5, 10, and 15 m/s. The highest erosion resistance of HCCI was at normal impact and the lowest at an angle of 30 deg, irrespective of velocity. The low erosion resistance at an oblique angle is due to large material removal by microcutting from ductile matrix and gross removal of carbides. The effect of velocity, over the studied range from 5 m/s to 15 m/s, on the increase in the erosion rate was minor. The change of impact velocity resulted in changing the slurry erosion mechanisms. At normal incidence, plastic indentation with extruded material of the ductile matrix was the dominant erosion mechanism at low impact velocity (5 m/s). With increasing impact velocity, the material was removed by the indentation of the ductile matrix and to smaller extent of carbide fracture. However, at high impact velocity (15 m/s), gross fracture and cracking of the carbides besides plastic indentation of the ductile matrix were the dominant erosion mechanisms.

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Fig. 1

(a) Optical photographs of HCCI microstructure and (b) SEM photographs of HCCI microstructure

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Fig. 2

Schematic diagram of the designed slurry erosion whirling-arm rig

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Fig. 3

Schematic diagram of impact velocity and impact angle

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Fig. 4

Variation of mass loss rate and accumulated mass loss with impact angle for HCCI

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Fig. 5

Variation of mass loss rate and accumulated mass loss with velocity for HCCI at impact angles of 30 deg and 90 deg

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Fig. 6

Variation of mass loss rate with kinetic energy for HCCI at impact angles of 30 deg and 90 deg

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Fig. 7

SEM features of eroded surfaces of HCCI at different impact angles

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Fig. 8

SEM photographs of HCCI impacted surface showing carbides removal

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Fig. 9

SEM photographs of HCCI impacted surfaces at velocities of (a) and (b) 5 m/s, (c) 10 m/s, and (d) and (e) 15 m/s and at impingement angle of 90 deg




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