Taguchi approach to erosion wear optimization of WC-10Co-4Cr sprayed austenitic steel subjected to equisized slurry

2018 ◽  
Vol 70 (9) ◽  
pp. 1774-1782 ◽  
Author(s):  
Gurmeet Singh ◽  
Satish Kumar ◽  
Satbir S. Sehgal
Keyword(s):  
Particle Size ◽  
Stainless Steel ◽  
Wear Resistance ◽  
Process Parameters ◽  
Rotational Speed ◽  
Solid Concentration ◽  
Erosion Wear ◽  
Pump Impeller ◽  
Content Type ◽  
Erosion Test

Purpose This paper aims to optimize the erosion wear analysis of slurry impeller material. Stainless steel (SS-410) was used as the pump impeller material. This erosion test was established to influence the rotational speed, solid concentration, time period and particle size. Fly ash was used as the erodent material. Design/methodology/approach The erosion wear experiments were performed at different particle size, rotational speed, time duration and solid concentration (by weight). These tests were performed at four different speeds of 750, 1,000, 1,250 and 1,500 rpm, and the time durations of these experiments are 75, 120,165 and 210 min. For protective coating, high-velocity oxygen-fuel spray process was used for depositing WC-10Co-4Cr coating on stainless steel. To investigate the influence of controlled process parameters on slurry erosion wear of pump impeller material, Taguchi method was used. Findings Results show that significant improvement in erosion wear resistance has been observed by using WC-10Co-4Cr coating. The process parameters affecting the erosion wear loss were in following order: time > rpm > concentration > particle size. The means of signal-to-noise ratio of stainless steel SS410 with and without coating vary from 93.56 to 54.02 and from 86.02 to 48.18, respectively. Originality/value For the erosion wear rate of both uncoated and coated stainless steel, the most powerful influencing factor was identified as time. The erosion test reveals that the coating exhibits ductile erosion mechanism and shows better erosion wear resistance (approximately two times) compared to uncoated stainless steel.

Erosion wear analysis of HVOF coated Colmonoy-88 and Stellite-6 micron layers on pump impeller steel by using the Taguchi's approach

2019 ◽  
Vol 72 (3) ◽  
pp. 455-463 ◽  
Author(s):  
Gurmeet Singh ◽  
Satish Kumar ◽  
Satbir Singh Sehgal ◽  
Shashi Bhushan Prasad
Keyword(s):  
Rotational Speed ◽  
Dominant Factor ◽  
Average Particle ◽  
Taguchi’S Method ◽  
Solid Concentration ◽  
Erosion Wear ◽  
Pump Impeller ◽  
Content Type ◽  
Stellite 6 ◽  
Nominal Size

Purpose This paper aims to depict the erosion performance of two HVOF-coated micron layers (Colmonoy-88 and Stellite-6) on pump impeller steel (SS-410) by using Taguchi's method. Taguchi's array (L16) was used to optimize the erosion wear (in terms of weight loss) by using four influencing parameters such as rotational speed, solid concentration, average particle size and time which were varied at four different levels. Design/methodology/approach The experiments were carried out by using a Ducom slurry tester with rotational speed in the range of 750-1,500 rpm, solid concentration of 35-65 per cent by weight, time period of 75-210 min and average particle sizes in the range of < 53 to 250 µm. Bottom Ash with a nominal size range of < 53 to 250 µm was used as erodent. The process parameters were optimized by using Taguchi's method. The ANOVA method was used to validate the results given by Taguchi's method. Findings The results revealed that the presence of both carbides and borides and the additional presence of Cr in Colmonoy-88 coating enhancing the slurry erosion resistance of Colmonoy-88 coating. Moreover, the chromium and tungsten carbide particles help in increasing the bond strength between the coating and the substrate material. Further, it was also found that the time was the most dominant factor as compared to other factors. Originality/value The very less work has been reported on optimization of erosion wear response of Colmonoy-88 and Stellite-6 coatings by using different design of experiment techniques. Further, the erosion wear mechanism of both coatings has been studied by using image j analysis software.

Tribological behaviour of WC-10Co4Cr coated slurry pipe materials

2018 ◽  
Vol 70 (9) ◽  
pp. 1721-1728 ◽  
Author(s):  
Kaushal Kumar ◽  
Satish Kumar ◽  
Munish Gupta ◽  
Hem Chander Garg
Keyword(s):  
Wear Resistance ◽  
Rotational Speed ◽  
Optimization Technique ◽  
Microstructural Analysis ◽  
Erosion Wear ◽  
Tribological Behaviour ◽  
Slurry Erosion ◽  
Time Duration ◽  
Content Type ◽  
Solid Liquid

Purpose This paper aims at erosion wear experimentation conducted on two piping materials, namely SS202 and SS304 to establish the effect of rotational speed, concentration and time period. Design/methodology/approach Erosion wear because of slurry flow is investigated using a slurry erosion pot tester. Fly ash is taken as erodent material having different solid concentrations lie in range 30 to 60per cent (by weight). Experiments are performed at four different speeds, i.e. 600; 900; 1,200; and 1,500 rpm for time duration of 90, 120, 150 and 180 min, respectively. To enhance erosion wear resistance of both piping materials, high-velocity-oxy-fuel coating technique is used to deposit WC-10Co4Cr coating. The parametric influence of erosion wear is optimized using Taguchi method. Findings The results show that significant improvement in erosion wear resistance is observed by deposition of WC-10Co4Cr coating. It is observed that rotational speed is found as highly influencing parameter followed by concentration and time duration. Parametric investigation of erosion wear is helpful to develop a procedure for minimizing the erosion wear in pipeline for the flow of solid-liquid mixture. Originality/value Slurry erosion wear of WC-10Co4Cr coated stainless steel (SS202 and SS304) is substantiated by extensive microstructural analysis and optimization technique.

Erosion characteristics on surface texture of additively manufactured AlSi10Mg alloy in SiO2 quartz added slurry environment

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Recep Demirsöz ◽  
Mehmet Erdl Korkmaz ◽  
Munish Kumar Gupta ◽  
Alberto Garcia Collado ◽  
Grzegorz M. Krolczyk
Keyword(s):  
Surface Roughness ◽  
Weight Loss ◽  
Wear Resistance ◽  
Erosive Wear ◽  
Oxide Ceramics ◽  
Slurry Erosion ◽  
Content Type ◽  
Test Setup ◽  
Quartz Sands ◽  
Erosion Test

Purpose The main purpose of this work is to explore the erosion wear characteristics of additively manufactured aluminium alloy. Additive manufacturing (AM), also known as three-dimensional (3D) manufacturing, is the process of manufacturing a part designed in a computer environment using different types of materials such as plastic, ceramic, metal or composite. Similar to other materials, aluminum alloys are also exposed to various wear types during operation. Production efficiency needs to be aware of its reactions to wearing mechanisms. Design/methodology/approach In this study, quartz sands (SiO2) assisted with oxide ceramics were used in the slurry erosion test setup and its abrasiveness on the AlSi10Mg aluminum alloy material produced by the 3D printer as selective laser melting (SLM) technology was investigated. Quartz was sieved with an average particle size of 302.5 µm, and a slurry environment containing 5, 10 and 15% quartz by weight was prepared. The experiments were carried out at the velocity of 1.88 (250 rpm), 3.76 (500 rpm) and 5.64 m/s (750 rpm) and the impact angles 15, 45 and 75°. Findings With these experimental studies, it has been determined that the abrasiveness of quartz sand prepared in certain particle sizes is directly related to the particle concentration and particle speed, and that the wear increases with the increase of the concentration and rotational speed. Also, the variation of weight loss and surface roughness of the alloy was investigated after different wear conditions. Surface roughness values at 750 rpm speed, 10% concentration and 75° impingement angle are 0.32 and 0.38 µm for 0 and 90° samples, respectively, with a difference of approximately 18%. Moreover, concerning a sample produced at 0°, the weight loss at 250 rpm at 10% concentration and 45° particle impact angle is 32.8 mg, while the weight loss at 500 rpm 44.4 mg, and weight loss at 750 rpm is 104 mg. Besides, the morphological structures of eroded surfaces were examined using the scanning electron microscope to understand the wear mechanisms. Originality/value The researchers verified that this specific coating condition increases the slurry wear resistance of the mentioned steel. There are many studies about slurry wear tests; however, there is no study in the literature about the quartz sand (SiO2) assisted slurry-erosive wear of AlSi10Mg alloy produced with AM by using SLM technology. This study is needed to fill this gap in the literature and to examine the erosive wear capability of this current material in different environments. The novelty of the study is the use of SiO2 quartz sands assisted by oxide ceramics in different concentrations for the slurry erosion test setup and the investigations on erosive wear resistance of AlSi10Mg alloy manufactured by AM.

Experimental study on the influence of friction pair material hardness on the tribological behaviors of water lubricated thrust bearings

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Xingxin Liang ◽  
Zhiyong Yang
Keyword(s):  
Stainless Steel ◽  
Wear Resistance ◽  
Abrasive Wear ◽  
Friction Pair ◽  
Aluminum Bronze ◽  
Heavy Load ◽  
Content Type ◽  
Thrust Bearings ◽  
Tribological Behaviors ◽  
Polymer Bearing

Purpose This paper aims to confirm that increasing the hardness of thrust collars can improve the load carrying capacity (LCC) and wear resistance of water lubricated thrust bearings (WTBs) made of polymers paired with non-polymeric thrust collars, and to design a WTB with high LCC and durability for a shaftless pump-jet propulsor of an autonomous underwater vehicle. Six kinds of WTBs were manufactured by matching aluminum bronze, stainless steel and silicon nitride with two different polymer bearing materials. Their tribological behaviors were tested and compared. Design/methodology/approach The tribological behaviors of the WTBs made with different materials were investigated experimentally on a specially designed test rig. Findings Aluminum bronze is not suitable for crafting thrust collars of heavy load WTBs due to severe abrasive wear. Two body abrasive wear first occurred between the thrust collar and the polymer bearing. Next, aluminum bronze wear particles were produced. The particles acted between the two materials and formed three body abrasive wear. Stainless steel/polymer bearings showed better wear resistance while Si3N4/polymer bearings were the best. Improving the hardness of thrust collars is significant to the LCC and service life of WTBs. Originality/value The wear mechanism of WTBs under heavy load conditions was revealed. Improving the hardness of the thrust collar was confirmed to be a preferable method to improve the wear resistance and LCC of WTBs. The results of this study may provide an important reference for the selection of water lubricated materials and the design of heavy load WTBs.

DOUBLE GLOW PLASMA SURFACE TITANIZING ON AISI 316 STAINLESS STEEL WITH IMPROVED WEAR RESISTANCE: EFFECTS OF PROCESS PARAMETERS

2019 ◽  
Vol 27 (07) ◽  
pp. 1950178
Author(s):  
YONG MA ◽  
NAIMING LIN ◽  
QIANG LIU ◽  
JIAOJUAN ZOU ◽  
XIUZHOU LIN ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Wear Resistance ◽  
Wear Rate ◽  
Process Parameters ◽  
Coating Thickness ◽  
Optimal Process ◽  
Plasma Surface ◽  
Aisi 316 Stainless Steel ◽  
Aisi 316 ◽  
Glow Plasma

Using the double glow plasma surface alloying technique, a titanizing coating with improved wear resistance can be prepared on AISI 316 stainless steel. The purpose of this paper is to investigate process parameter effects by orthogonal array design. Four main factors, titanizing temperature, holding time, voltage difference and electrode distance, are adopted in orthogonal experiments. For each factor, four levels are set. The range analysis is used to investigate the factor and level influences on the coating thickness and specific wear rate. Meanwhile, the analysis of variance method is applied to calculate the contributions of each factor. The results indicate that temperature is most critical. In balancing the coating thickness and the wear property, the optimal process parameters are 950∘C, 3[Formula: see text]h, 200[Formula: see text]V and 18[Formula: see text]mm. Corresponding to the optimal process, the thickness and the specific wear rate of the titanizing coating are 10[Formula: see text][Formula: see text]m and 2.609E−05 mm3⋅ N−1⋅ m−1, respectively.

Optimization of friction stir welding process parameters for AA6063-ETP copper using central composite design

2020 ◽  
Vol 17 (4) ◽  
pp. 491-507 ◽  
Author(s):  
Nitin Panaskar ◽  
Ravi Prakash Terkar
Keyword(s):  
Experimental Data ◽  
Tensile Strength ◽  
Friction Stir Welding ◽  
Process Parameters ◽  
Rotational Speed ◽  
Traverse Speed ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Central Composite

Purpose Recently, several studies have been performed on lap welding of aluminum and copper using friction stir welding (FSW). The formation of intermetallic compounds at the weld interface hampers the weld quality. The use of an intermediate layer of a compatible material during welding reduces the formation of intermetallic compounds. The purpose of this paper is to optimize the FSW process parameters for AA6063-ETP copper weld, using a compatible zinc intermediate filler metal. Design/methodology/approach In the present study, a three-level, three-factor central composite design (CCD) has been used to determine the effect of various process parameters, namely, tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil on ultimate tensile strength of the weld. A total of 60 experimental data were fitted in the CCD. The experiments were performed with tool rotational speeds of 1,000, 1,200 and 1,400 rpm each of them with tool traverse speeds of 5, 10 and 15 mm/min. A zinc inter-filler foil of 0.2 and 0.4 mm was also used. The macrograph of the weld surface under different process parameters and the tensile strength of the weld have been investigated. Findings The feasibility of joining 3 mm thick AA6063-ETP copper using zinc inter-filler is established. The regression analysis showed a good fit of the experimental data to the second-order polynomial model with a coefficient of determination (R2) value of 0.9759 and model F-value of 240.33. A good agreement between the prediction model and experimental findings validates the reliability of the developed model. The tool rotational speed, tool traverse speed and thickness of inter-filler zinc foil significantly affected the tensile strength of the weld. The optimal conditions found for the weld were, rotational speed of 1,212.83 rpm and traverse speed of 9.63 mm/min and zinc foil thickness is 0.157 mm; by using optimized values, ultimate tensile strength of 122.87 MPa was achieved, from the desirability function. Originality/value Aluminium and copper sheets could be joined feasibly using a zinc inter-filler. The maximum tensile strength of joints formed by inter-filler (122.87 MPa) was significantly better as compared to those without using inter-filler (83.78 MPa). The optimum process parameters to achieve maximum tensile strength were found by CCD.

scholarly journals Controlling the porosity of 316L stainless steel parts manufactured via the powder bed fusion process

2019 ◽  
Vol 25 (1) ◽  
pp. 162-175 ◽  
Author(s):  
Abdullah AlFaify ◽  
James Hughes ◽  
Keith Ridgway
Keyword(s):  
Stainless Steel ◽  
Layer Thickness ◽  
Exposure Time ◽  
Process Parameters ◽  
Pulsed Laser ◽  
Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Point Distance ◽  
Part Density

Purpose The pulsed-laser powder bed fusion (PBF) process is an additive manufacturing technology that uses a laser with pulsed beam to melt metal powder. In this case, stainless steel SS316L alloy is used to produce complex components. To produce components with acceptable mechanical performance requires a comprehensive understanding of process parameters and their interactions. This study aims to understand the influence of process parameters on reducing porosity and increasing part density. Design/methodology/approach The response surface method (RSM) is used to investigate the impact of changing critical parameters on the density of parts manufactured. Parameters considered include: point distance, exposure time, hatching distance and layer thickness. Part density was used to identify the most statistically significant parameters, before each parameter was analysed individually. Findings A clear correlation between the number and shape of pores and the process parameters was identified. Point distance, exposure time and layer thickness were found to significantly affect part density. The interaction between these parameters also critically affected the development of porosity. Finally, a regression model was developed and verified experimentally and used to accurately predict part density. Research limitations/implications The study considered a range of selected parameters relevant to the SS316L alloy. These parameters need to be modified for other alloys according to their physical properties. Originality/value This study is believed to be the first systematic attempt to use RSM for the design of experiments (DOE) to investigate the effect of process parameters of the pulsed-laser PBF process on the density of the SS316L alloy components.

Powder characterization and part density for powder bed fusion of 17-4 PH stainless steel

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sean Daniel Dobson ◽  
Thomas Louis Starr
Keyword(s):  
Particle Size ◽  
Stainless Steel ◽  
Flow Behavior ◽  
Full Density ◽  
Powder Bed Fusion ◽  
Metal Powders ◽  
Production Environment ◽  
Content Type ◽  
Powder Bed ◽  
Part Density

Purpose Characteristics of the metal powder are a key factor in the success of powder bed fusion (PBF) additive manufacturing. Powders for PBF from different manufacturers may have a different particle size and/or bulk packing and flow behavior. Powder properties change as the powder is reused for multiple builds. This study seeks to measure the variability of commercial 17-4 PH stainless steel powders to determine the effect of powder variability on part density and demonstrate characterization methods that ensure part quality. Design/methodology/approach Commercial atomized metal powders from four different vendors were produced with two different atomizing gases (N2 and argon). Powder was characterized in both new and extensively reused conditions. All powders were characterized for flow and packing behavior, particle size and internal porosity. Coupons were manufactured using the laser PBF process with optimized scan strategy and exposure parameters. The quality of fabricated parts was measured using bulk density measurement. Findings Despite differences in powder flowability and particle size, fully dense parts (>99 per cent) were produced using all powders, except one. Residual porosity in these parts appeared to result from gas trapped in the powder particles. The powder with extensive reuse (400+ h in machine fabrication environment) exhibited reduced flowability and increased fraction of fine particles, but still produced full density parts. Originality/value This study demonstrates that full density parts can be fabricated using powders with a range of flowability and packing behavior. This suggests that a single flowability measurement may be sufficient for quality assurance in a production environment.

Parameters optimization in FSW of polypropylene based on RSM

2015 ◽  
Vol 11 (1) ◽  
pp. 32-42 ◽  
Author(s):  
K Panneerselvam ◽  
Kasirajan Lenin
Keyword(s):  
Process Parameters ◽  
Rotational Speed ◽  
Optimization Techniques ◽  
Parameters Optimization ◽  
Tool Rotational Speed ◽  
Content Type ◽  
Friction Stir ◽  
Optimization Of Process Parameters ◽  
Output Characteristics ◽  
Tool Pin

Purpose – The purpose of this paper is to weld polypropylene (PP) material by friction stir welding (FSW) process. The input process parameters considered were: tool pin profile, feed rate and tool rotational speed and the process output characteristics were tensile strength, Shore-D hardness, Rockwell hardness, Izod strength, Charpy strength and nugget area. Design/methodology/approach – Optimization of process parameters were carried out based on response surface methodology (RSM) and significant parameters were obtained by performing analysis of variance (ANOVA). Findings – The optimized results were the threaded pin profile for feed of 60 mm/min and tool rotational speed of 1,500 rpm. A confirmation test was carried out to verify the optimized results. Originality/value – In this paper, the process parameters were optimized based on RSM. This is newly adopted optimization techniques in the FSW process of PP materials and also it gives better results.

SLURRY EROSION BEHAVIOR OF HVOF SPRAYED WC-12Co AND Cr3C2-25NiCr COATINGS DEPOSITED ON 16Cr5Ni STAINLESS STEEL

2020 ◽  
Vol 27 (08) ◽  
pp. 1950193
Author(s):  
JIN DU ◽  
JIANFENG ZHANG ◽  
JINKUN XIAO ◽  
CHAO ZHANG
Keyword(s):  
Particle Size ◽  
Stainless Steel ◽  
Significant Influence ◽  
Rotational Speed ◽  
Erosion Rate ◽  
Martensitic Stainless Steel ◽  
Composite Coatings ◽  
Dominant Factor ◽  
Slurry Erosion ◽  
Erosion Behavior

Slurry erosion behaviors of HVOF WC-12Co and Cr3C2-25NiCr coatings as well as 16Cr5Ni martensitic stainless steel were investigated in the present paper. Erosion experiments were carried out using slurry with different rotational speeds, particle size and concentration to evaluate their influences on the coatings. It was found that the rotational speed had the most significant influence on WC-12Co coating, whereas the erosion particle size was a more dominant factor for the Cr3C2-25NiCr coating. Nevertheless, the effect of concentration was most important in the case of 16Cr5Ni steel. It is demonstrated that cermet composite coatings could effectively enhance the resistance of slurry erosion, and the WC-12Co coating exhibits a minimum erosion rate compared with the steel and Cr3C2-25NiCr coating. 16Cr5Ni steel and WC-12Co coating showed ductile and brittle mechanisms, respectively, whereas Cr3C2-25NiCr exhibited multiple mechanisms of ductile and brittle, dominantly ductile.

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