scholarly journals Reducing the mechanical wear of elbows and pipes due to solid particles flow by using nano coating technique

2021 ◽  
Vol 11 (1) ◽  
Author(s):  
Ali Sadiq Al-Ithari ◽  
Nabeel Al-Zurfi ◽  
Laith Zbbal Abd U. L. Kareem
Keyword(s):  
Erosion Rate ◽  
Low Carbon Steel ◽  
Operating Conditions ◽  
Solid Particles ◽  
Low Carbon ◽  
Tungsten Carbides ◽  
Operation Condition ◽  
Mechanical Wear ◽  
Nano Coating ◽  
Pin On Disc

AbstractThis work investigated reasons and factors that cause the failure due to mechanical wear (Erosion) for the inside surface of elbows and pipes used in cement transportation which manufactures from low carbon steel and finds out a method for reducing this failure. The technique of Nano-coating layers is used to coat the surface of samples with layers of nanoparticles of tungsten carbides of different thicknesses of (30, 40, and 50 μm). The test was done for these samples by placing them inside the elbow under the same operating conditions, pin on disc test. The results of the test under the same operation condition showed a decrease in erosion rate by 71% for the sample coated with 50 μm of layer, while the results of the pin on disc test showed a decrease in erosion rate by 97% for the thickness of 50 μm as this test is done under ideal testing conditions. The decrease in wear rate for elbow and pipes will increase their life work two times at least and that reduces the cost of maintenance by about 75%. The numerical simulation was also implemented to simulate the erosion profile inside the elbow, and the agreement with experimental results was 90%.

scholarly journals Reducing the Mechanical Wear of Elbows and Pipes Due to Solid Particles Flow by Using Nano Coating Technique

2021 ◽  
Author(s):  
Ali Sadiq Al-Ithari ◽  
Nabeel Al-Zurfi ◽  
Laith Zbbal Abd Ul Kareem
Keyword(s):  
Erosion Rate ◽  
Low Carbon Steel ◽  
Operating Conditions ◽  
Solid Particles ◽  
Low Carbon ◽  
Tungsten Carbides ◽  
Sem Images ◽  
Mechanical Wear ◽  
Nano Coating ◽  
Pin On Disc

Abstract The failure problems of elbows and pipes facing a lot of industrial foundations like Cement Plants. This work investigated reasons and factors that cause the failure due to mechanical wear (Erosion) for the inside surface of elbows and pipes used in cement transportation (pneumatic conveyor) which manufactures from low carbon steel and finds out a method for reducing this failure. The technique of thermal spraying is using to coat the surface of samples with layers of nanoparticles of tungsten carbides (WC) of different thicknesses (30, 40, and 50μm). The test was done for these samples by placing them inside the elbow under the same operating conditions, moreover the standard test (pin on disc). The results showed a decrease in erosion rate by 71% for the sample coated with 50μm of WC layer, while the results of the pin on disc test showed a decrease in erosion rate by 97% for the thickness of 50μm. The SEM Images showed a coating thickness layer of more than 50μm will be subjected to flacking and failure. The numerical simulation was also implemented to simulate the erosion profile inside the elbow, and the agreement with experimental results was 90%.

scholarly journals Reducing Mechanical Wear of Elbows and Pipes Due to Solid Particles Flow by Using Nano Coating Technique

2020 ◽  
Author(s):  
Laith Abd UL Kareem ◽  
Ali Sadiq AlIthari ◽  
Nabeel AlZurfi
Keyword(s):  
High Velocity ◽  
Low Carbon Steel ◽  
Solid Particles ◽  
Pipe Material ◽  
Low Carbon ◽  
Tungsten Carbides ◽  
Mechanical Wear ◽  
Spray Process ◽  
Nano Coating ◽  
Pin On Disc

Abstract The problem of failure for elbows and pipes due to the effects of solid particles flow with a high velocity, facing a lot of industrial foundations now days. This work investigated factors that cause failure by mechanical wear inside elbows and pipes of cement transportation which manufacturing from low carbon steel (St-52-3) and find out a method for reducing this mechanical wear. Coating with layers of nanoparticles of tungsten carbides (WC) using a thermal spray process with a high-velocity oxy-fuel technique (HVOF) is one of those methods. The coating process was done for samples from the same material of elbow and pipe material. Some tests were done for these samples with different coating thicknesses (30, 40, and 50 µm) by placing them inside the elbow as well as standard wear tests (pin on disc). The results showed a decrease in the mechanical wear for the sample coated with 50 µm of WC layer by 71% compared with that without coating, while the results of the pin on disc test showed a decrease in wear about 97% for the sample coated with 50 µm. The photographs of the scanning electron microscope (SEM) were used to determine the thickness of the coating layer on samples. The numerical simulation was also implemented to simulate the erosion profile inside the elbow by using the commercial code STAR CCM + based on the CFD technique; the predicted results showed a good agreement with the experimental data with accuracy reaches 94%.

scholarly journals Microstructure and Properties of Heat Affected Zone in High-Carbon Steel after Welding with Fast Cooling in Water

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5059
Author(s):  
Michail Nikolaevich Brykov ◽  
Ivan Petryshynets ◽  
Miroslav Džupon ◽  
Yuriy Anatolievich Kalinin ◽  
Vasily Georgievich Efremenko ◽  
...  
Keyword(s):  
Carbon Steel ◽  
Heat Affected Zone ◽  
Welded Joints ◽  
High Carbon Steel ◽  
Low Carbon Steel ◽  
Tensile Tests ◽  
Low Carbon ◽  
High Carbon ◽  
Mechanical Wear ◽  
Fast Cooling

The purpose of the research was to obtain an arc welded joint of a preliminary quenched high-carbon wear resistant steel without losing the structure that is previously obtained by heat treatment. 120Mn3Si2 steel was chosen for experiments due to its good resistance to mechanical wear. The fast cooling of welding joints in water was carried out right after welding. The major conclusion is that the soft austenitic layer appears in the vicinity of the fusion line as a result of the fast cooling of the welding joint. The microstructure of the heat affected zone of quenched 120Mn3Si2 steel after welding with rapid cooling in water consists of several subzones. The first one is a purely austenitic subzone, followed by austenite + martensite microstructure, and finally, an almost fully martensitic subzone. The rest of the heat affected zone is tempered material that is heated during welding below A1 critical temperature. ISO 4136 tensile tests were carried out for the welded joints of 120Mn3Si2 steel and 09Mn2Si low carbon steel (ASTM A516, DIN13Mn6 equivalent) after welding with fast cooling in water. The tests showed that welded joints are stronger than the quenched 120Mn3Si2 steel itself. The results of work can be used in industries where the severe mechanical wear of machine parts is a challenge.

scholarly journals EXTENSION OF THE RESOURCE OF THE BURNER SWIRL BLADES OF THE BOILER TPP-312

2020 ◽  
Vol 42 (3) ◽  
pp. 61-67
Author(s):  
S.G. Kobzar ◽  
I.I. Borisov ◽  
A.A. Khalatov
Keyword(s):  
Low Carbon Steel ◽  
Pulverized Coal ◽  
Operating Conditions ◽  
Low Carbon ◽  
Blade Surface ◽  
Boiler Furnace ◽  
Subsequent Determination ◽  
Steel 20 ◽  
Burner Operation ◽  
Corrosion Of Steel

Numerical research of high-temperature corrosion of steel blades of the swirler of a pulverized coal burner of the TPP-312 boiler in real conditions of its operation is carried out. Data on the dynamics of oxidation of the blade surface for two steels and different operating conditions of the burners were obtained. The results of the calculation allow a reasonable assessment of the service life of the blades of the burner device. Corrosion rate calculations were performed based on the results of computer simulation of pulverized coal combustion in the boiler volume with subsequent determination of the temperature field on the blade surface. The corrosion dynamics was determined using the experimental oxidation constants of steel given in the literature. Data were obtained for two types of low-carbon steel, two different modes of burner operation, for the number of blades 8 and 24, and for different distances of burner blades from the embrasure of the boiler furnace, a total of 16 different variants were calculated. Calculations have shown that with increasing the distance of the blades from the embrasure of the furnace, corrosion is significantly reduced. The highest corrosion, which in its absolute value is comparable to the thickness of the blade, occurs for the disconnected burner with blades from Art. 3. The lowest corrosion occurs for the working burner with blades made from steel 20 (reduction of corrosion by 4 times), and for the disconnected burner this dependence is much smaller (reduction of corrosion by 30… 40%). References 6, Figures 5

Tribology of drawing lubricants for low carbon steel

2014 ◽  
Vol 66 (6) ◽  
pp. 640-644 ◽  
Author(s):  
Bhanudas Dattatraya Bachchhav ◽  
Geeta S. Lathkar ◽  
Harijan Bagchi
Keyword(s):  
Low Carbon Steel ◽  
Carbon Steels ◽  
Sliding Contact ◽  
Stribeck Curve ◽  
Additive Concentration ◽  
Low Carbon ◽  
Content Type ◽  
Analysis Technique ◽  
Pin On Disc ◽  
Selection Of

Purpose – This paper aims to present a study of frictional characteristics of steel/die steel pair under sliding contact in presence of a set of formulated lubricants. AISI 1010 low carbon steels, although being strong, are less formable grades of steel and require appropriate selection of lubricants in tribological conditions. Design/methodology/approach – A total of three mineral-based lubricating blends were formulated for varying concentration of ester. Plan of experiments, based on Taguchi’s analysis technique were performed using dedicated test rig based on “pin-on-disc” principle. Findings – A correlation was established between additive concentration, sliding speed and pressure with coefficient of friction by multiple linear regression. On the basis of experimental results and S/N ratio analysis, ranking of the parameters has been done. A possible regime of working with such lubricants is also suggested. Practical implications – Due to voluminous data involved, a few dominant process parameters were taken into consideration for the study. Originality/value – This paper is highlighting the tribo-effects of additives to render it as suitable lubricant in sliding contact conditions. This paper also suggested an approach for selection of optimum regime of working in the light of “Stribeck Curve” for ester-containing lubricating oils.

Experimental and Finite Element Simulation of Wear in Nanostructured NiAl Coating

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
H. Tavoosi ◽  
S. Ziaei-Rad ◽  
F. Karimzadeh ◽  
S. Akbarzadeh
Keyword(s):  
Finite Element ◽  
Steel Substrate ◽  
Three Dimensional ◽  
Low Carbon Steel ◽  
Nanostructured Material ◽  
Operating Conditions ◽  
Nanoindentation Test ◽  
Fe Model ◽  
Low Carbon ◽  
Fe Method

In this paper, the wear of nanostructured NiAl coating was studied both experimentally and numerically. First, the nanocrystalline NiAl intermetallic powder was synthesized by mechanical alloying (MA) of aluminum and Ni powders. The coatings were deposited onto the low carbon steel substrate using high velocity oxy-fuel (HVOF) technique. Nanoindentation test was conducted to find out the mechanical properties of the coating. The dry wear tests were then performed using a pin-on-block test rig under different operating conditions. Finally, finite element (FE) method was employed to model the wear characteristics of the prepared nanostructured material. A three-dimensional (3D) FE model was created and used to simulate the pin-on-block experiments. The results show that the volume losses predicted by the numerical analysis are in good agreement with the experimental data.

Preliminary evaluations on development of new materials for hip joint femoral head

2017 ◽  
Vol 233 (5) ◽  
pp. 885-899 ◽  
Author(s):  
Amit Aherwar ◽  
Amar Patnaik ◽  
Marjan Bahraminasab ◽  
Amit Singh
Keyword(s):  
Femoral Head ◽  
Testing Machine ◽  
Operating Conditions ◽  
Test Method ◽  
Chromium Alloy ◽  
Cobalt Chromium ◽  
Corrosion Properties ◽  
Mechanical Wear ◽  
Hardness Tester ◽  
Pin On Disc

Development and selection of a proper biomaterial with diverse properties (i.e. physical, mechanical, wear, corrosion, and many others) for hip femoral head is one of the most exigent tasks. Improper material often causes component failure during functioning. Therefore, in this study, a series of implant materials containing tungsten of different weight percentages were fabricated by high temperature vacuum casting induction furnace and the physical, mechanical, wear, and corrosion properties were examined. The proportions were varied from 0 wt% to 4 wt% in a cobalt–chromium alloy (Co–30Cr–4Mo–1Ni). The mechanical properties were tested by the micro-hardness tester and the compression testing machine, while the wear performance was analyzed through a pin-on-disc tribometer under different operating conditions at room temperature. Corrosion resistance was analyzed under NaCl solution by the electrochemical test method. Due to the conflict between the properties obtained, the Vise Kriterijumska Optimizacija Kompromisno Resenjemeaning (VIKOR) method integrated with analytic hierarchy process (AHP) was applied to choose the best material among the set of alternatives, where AHP was used to determine criteria weights, and VIKOR approach was used to rank the alternatives. From the results obtained, it was found that Co–30Cr–4Mo–1Ni implant material containing 2 wt% tungsten provides the best combination of the properties for a given application (i.e. hip femoral head).

Effect of Ceramic Particle Reinforcement on the Erosion Resistance of Thermally Sprayed De-Icing Systems

2021 ◽  
Author(s):  
Shahed Taghian Dehaghani ◽  
André McDonald ◽  
Ali Dolatabadi
Keyword(s):  
Metal Matrix ◽  
Turbine Blades ◽  
Matrix Material ◽  
Low Carbon Steel ◽  
Erosive Wear ◽  
Cold Spraying ◽  
Solid Particles ◽  
Flame Spraying ◽  
Low Carbon ◽  
Wear Rates

Abstract Developing effective heating systems to prevent ice accretion on the surface of wind turbine blades and aircraft wings is of great significance for extreme cold environments. However, due to high velocity impingement of water droplets and solid particles on the surface of these components, an appreciable degree of surface material degradation may occur. In this study, nickel-chromium-aluminum-yttrium (NiCrAlY) was chosen as a metal matrix material for a coating-based heating system. Pure ceramic powders, namely, alumina and titania, and a cermet powder, tungsten carbide-cobalt (WC-12Co), were mechanically admixed with NiCrAlY powder and deposited to fabricate reinforced metal matrix composite (MMC) coatings. The powders were deposited on cylindrical low carbon steel bars by using flame spraying. The specimens were placed in a wind tunnel to conduct a comparative investigation of their erosive wear resistance under water droplet impact. A cold spraying unit was used for solid particle impact erosion tests. The erosive wear rates were quantified by measuring mass loss. The experimentally obtained results showed noticeably lower wear rate in NiCrAlY-WC-12Co and NiCrAlY-titania coatings compared to the other coatings. The results suggest that certain MMC coatings could be effectively employed to decrease the erosion rate of coating-based heating elements.

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