Slurry erosion behavior of plasma sprayed coating on turbine steel

2019 ◽  
Vol 71 (1) ◽  
pp. 1-9 ◽  
Author(s):  
Sarbjeet Kaushal ◽  
Satnam Singh
Keyword(s):  
Abrasive Wear ◽  
Rotational Speed ◽  
Silica Sand ◽  
Average Particle ◽  
Slurry Erosion ◽  
Content Type ◽  
Erosion Behavior ◽  
Turbine Steel ◽  
Sprayed Coating ◽  
Plasma Sprayed

PurposeThe purpose of this paper is to study the effect of slurry erosion at different parameters on plasma sprayed Cr3C2coated 13Cr4Ni turbine steel and compare the results of coated steel with bare steel.Design/methodology/approachCr3C2+ 25NiCr coating was successfully developed on 13Cr4Ni turbine steel using plasma spraying method. The slurry erosion test was performed using a simulated erosion testing rig. The commercially available silica sand was used as abrasive media and the effect of concentration (ppm), average particle sizes and rotational speed on the slurry erosion behavior were studied at 300 and 900 impact angles. Developed coatings were characterized by scanning electron microscope, XRD, EDS and micro hardness tests and study of erosion wear.FindingsResults revealed that three times higher hardness of coatings was obtained because of the hard phases of chromium carbide and nickel carbide, which restricted the abrasive wear in comparison to uncoated steel. Lower abrasive wear was observed at 900 impact angle coupled with lower levels of slurry concentration and rotational speed. Further, it was observed that initially cumulative mass loss rate was high which gets stabilized after the surface become smooth and on exposing for higher periods. Overall results indicated that erosive wear was reduced significantly by the application of developed coating.Originality/valueThe developed plasma sprayed coating is very useful to enhance the service life of turbine steel by lowering the effect of slurry erosion.

Mechanical properties and erosive behaviour of 10TiO2-Cr2O3 coated CA6NM turbine steel under accelerated conditions

2019 ◽  
Vol 16 (1) ◽  
pp. 64-70 ◽  
Author(s):  
Khushdeep Goyal
Keyword(s):  
Mechanical Properties ◽  
Mass Loss ◽  
Average Particle Size ◽  
Average Particle ◽  
Slurry Erosion ◽  
Experimental Conditions ◽  
Content Type ◽  
Uncoated Steel ◽  
Erosion Test ◽  
Turbine Steel

Purpose This paper aims to evaluate the mechanical properties and slurry erosion behaviour of 10TiO2-Cr2O3 coated turbine steel. Design/methodology/approach Slurry erosion experiments were performed on the coated turbine steel specimens using slurry erosion test rig under accelerated conditions such as rotational speed, average particle size and slurry concentration. Surface roughness tester, Vickers microhardness tester and scanning electron microscope were used to analyse erosion mechanism. Findings Under all experimental conditions, 10TiO2-Cr2O3 coated steel showed better slurry erosion resistance in comparison with Al2O3 coated and uncoated steel specimens. Each experimental condition indicated a significant effect on the erosion rate of both coatings and uncoated steel. The surface analysis of uncoated eroded specimen revealed that plastic deformation, ploughing and deep craters formation were the reasons for mass loss, whereas microchipping, ploughing and microcutting were the reasons for mass loss of coated specimens. Originality/value The present investigation provides novel insight into the comparative slurry erosion performance of high velocity oxy fuel deposited 10TiO2-Cr2O3 and Cr2O3 coatings under various environmental conditions. To form modified powder, 10 Wt.% TiO2 was added to 90 Wt.% Cr2O3.

Slurry erosion performance study of HVFS sprayed Ni-20Al2O3 and Ni-15Al2O3-5TiO2 coatings under hydro accelerated conditions

2018 ◽  
Vol 70 (4) ◽  
pp. 805-817 ◽  
Author(s):  
Rajeev Kumar ◽  
Sanjeev Bhandari ◽  
Atul Goyal ◽  
Yogesh Kumar Singla
Keyword(s):  
Particle Size ◽  
Rotational Speed ◽  
Average Particle Size ◽  
Synergetic Effect ◽  
Average Particle ◽  
Flame Spray ◽  
Slurry Erosion ◽  
Content Type ◽  
Slurry Concentration ◽  
Ca6nm Steel

Purpose This paper aims to cover all the aspects of development, investigation and analysis phases to evaluate the slurry erosion performance of test coatings. The powders having composition of Ni-20Al2O3 and Ni-15Al2O3-5TiO2 were deposited on CA6NM grade turbine steel by using high velocity flame spray (HVFS) technique. The characterization of the coatings was done with the help of SEM/EDS and XRD techniques. Various properties such as micro-hardness and bonding strength of the coatings were also evaluated. Thereafter, these coatings were subjected to an indigenously developed high speed slurry erosion tester at different levels of rotational speed, erodent particle size and slurry concentration. The effect of these parameters on the erosion behavior of coatings was also evaluated. The slurry erosion tests and SEM of the eroded surfaces revealed remarkable improvement in slurry erosion resistance of Ni-15Al2O3-5TiO2 coating in comparison with Ni-20Al2O3 coating. Design/methodology/approach Two different compositions of HVFS coating were developed onto CA6NM steel. Subsequently, these coatings were evaluated by means of mechanical and microstructural characterization. Further, slurry erosion testing was done to analyze the erosive wear behavior of developed coatings. Findings The coatings were successfully developed by HVFS process. Cross-sectional microscopic analysis of sprayed coatings revealed a continuous and defect-free contact between substrate and coating. Ni-15Al2O3-5TiO2 coating showed higher value of bond strength in comparison with Ni-20Al2O3 coating. Under all the testing conditions, Ni-15Al2O3-5TiO2 coatings showed higher resistance to slurry erosion in comparison with Ni-20Al2O3 coatings. Rotational speed, average particle size of erodent and slurry concentration were found to have proportional effect on specific mass loss of coatings. The mixed behavior (brittle as well as ductile) of the material removal mechanism was observed for the coatings. Originality/value From the literature review, it was found that researchers have documented the various studies on Ni-Al2O3, Ni-TiO2 and Al2O3-TiO2 coatings. No one has ascertained the synergetic effect of Alumina and Titania on the slurry erosion performance of Nickel-based coating. In view of this, the authors have developed Ni-Al2O3 and Ni-Al2O3-TiO2 coatings, and an attempt has been made to compare their mechanical, microstructural and slurry erosion characteristics.

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.

Artificial neural network model for evaluation the effect of surface properties amendment on slurry erosion behavior of AISI 5117 steel

2016 ◽  
Vol 68 (6) ◽  
pp. 676-682 ◽  
Author(s):  
Bahaa Saleh ◽  
Ayman A. Aly
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Operating Conditions ◽  
Computational Technique ◽  
Slurry Erosion ◽  
Content Type ◽  
Erosion Behavior ◽  
Wide Range ◽  
Artificial Neural ◽  
Effect Of Surface

Purpose The aim of this paper is to evaluate the effect of surface treatment on slurry erosion behavior of AISI 5,117 steel using artificial neural network (ANN) technique. Design/methodology/approach The slurry erosion wear behavior of electroless nickel-phosphorus (Ni-P) coated, carburized and untreated AISI 5,117 alloy steel was investigated experimentally and theoretically using ANN technique based on error back propagation learning algorithm. Findings From the obtained results, it can be concluded that the proposed AAN model can be successfully used for evaluating slurry erosion behavior of the Ni-P coated, carburized and untreated AISI 5,117 steel for wide range of operating conditions and Ni-P coating and carburizing improve the slurry erosion resistance of AISI 5,117 steel; however, the coating is more efficient. Originality/value Slurry erosion is a serious problem for the performance, reliability and service life of engineering components used in many industrial applications. To improve the performance of these components, engineering surface technologies have been attracting a great deal of attention. The extent of slurry erosion is dependent on a wide range of variables. To account all variables that effect on erosion behavior, prediction of erosion behavior by soft computational technique is one of the most important requirements. ANN has the ability to tackle the problem of complex relationships among variables that cannot be accomplished by traditional analytical methods.

High temperature erosion behavior of plasma sprayed Al2O3 coating on AISI-304 stainless steel

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Gaurav Prashar ◽  
Hitesh Vasudev
Keyword(s):  
High Temperature ◽  
Aisi 304 ◽  
Content Type ◽  
X Ray ◽  
Hot Air ◽  
Air Jet ◽  
Erosion Test ◽  
Sprayed Coating ◽  
Plasma Sprayed ◽  
High Temperature Erosion

Purpose In the present study, Al2O3 coatings were deposited on stainless steel AISI-304 material by using atmospheric plasma spraying technique to combat high temperature solid particle erosion. The present aims at the performance analysis of Al2O3 coatings at high temperature conditions. Design/methodology/approach The erosion studies were carried out at a temperature of 400°C by using a hot air-jet erosion tester for 30° and 90° impingement angles. The possible erosion mechanisms were analyzed from scanning electron microscope (SEM) micrographs. Surface characterization of the powder and coatings were conducted by using an X-ray diffractometer, SEM, equipped with an energy dispersive X-ray analyzer. The porosity, surface roughness and micro-hardness of the as-sprayed coating were measured. This paper discusses outcomes of the commonly used thermal spray technology, namely, the plasma spray method to provide protection against erosion. Findings The plasma spraying method was used to successfully deposit Al2O3 coating onto the AISI 304 substrate material. Detailed microstructural and mechanical investigations were carried out to understand the structure-property correlations. Major findings were summarized as under: the erosive wear test results indicate that the plasma sprayed coating could protect the substrate at both 30° and 90° impact angles. The coating shows better resistance at an impact angle of 30° compared with 90°, which is related to the pinning and shielding effect of the alumina particle. The major erosion wear mechanisms of Al2O3 coating were micro-cutting, micro-ploughing, splat removal and detachment of Al2O3 hard particles. Originality/value In the current study, the authors have followed the standard testing method of hot air jet erosion test as per American society for testing of materials G76-02 standard and reported the erosion behavior of the eroded samples. The coating was not removed at all even after the erosion test duration i.e. 10 min. The erosion test was continued till 3 h to understand the evolution of coatings and the same has been explained in the erosion mechanism. The outcome of the present study may be used to minimize the high temperature erosion of AISI-304 substrate.

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.

Effect of Impact Angle on Slurry Erosion Behavior and Mechanisms of Carburized AISI 5117 Steel

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Y. M. Abd-Elrhman ◽  
A. Abouel-Kasem ◽  
K. M. Emara ◽  
S. M. Ahmed
Keyword(s):  
Erosion Resistance ◽  
Impact Angle ◽  
Silica Sand ◽  
Ductile Material ◽  
Hardness Profile ◽  
Slurry Erosion ◽  
Erosion Behavior ◽  
Nominal Size ◽  
Impact Angles ◽  
The Impact

The paper reports the influence of carburizing on the slurry erosion behavior of AISI 5117 steel using a whirling-arm rig. The microstructure and hardness profile of the surface layer of carburized steel were investigated. For characterizing the slurry damage process and for better understanding of material removal at different angles, scanning electron microscope (SEM) images at different locations on eroded surface using stepwise erosion combined with relocation SEM were presented. The study is also focused on studying the erosion wear resistance properties of AISI 5117 steel after carburizing at different impact angles. The tests were carried out with particle concentration of 1 wt. %, and the impact velocity of slurry stream was 15 m/s. Silica sand has a nominal size range of 250 – 355 μm was used as an erodent. The results showed that, carburizing process of steel increased the erosion resistance and hardness compared with untreated material for all impact angles. The erosion resistance of AISI 5117 steel increases by 75%, 61%, 33%, 10% at an impact angle of 30 deg, 45 deg, 60 deg, and 90 deg, respectively, as result of carburizing, i.e., the effectiveness of carburizing was the highest at low impact angles. Treated and untreated specimens behaved as ductile material, and the maximum mass loss appeared at impact angle of 45 deg. Plough grooves and cutting lips appeared for acute impact angle, but the material extrusions were for normal impact angles. The erosion traces were wider and deeper for untreated specimens comparing by the shallower and superficial ones for the carburized specimens. Chipping of the former impact sites by subsequent impact particles plays an important role in developing erosion.

Erosive Wear Study of HVOF Spray Cr3C2–NiCr Coated CA6NM Turbine Steel

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
Deepak Kumar Goyal ◽  
Harpreet Singh ◽  
Harmesh Kumar ◽  
Varinder Sahni
Keyword(s):  
High Speed ◽  
Protective Coatings ◽  
Average Particle Size ◽  
Erosive Wear ◽  
Average Particle ◽  
Slurry Erosion ◽  
Spray Process ◽  
Hvof Spray ◽  
Turbine Steel ◽  
Ca6nm Steel

Degradation of surfaces of hydroturbine components caused by impact of abrasive particles carried by flowing water is a serious issue. To counteract the same, surface modification of turbine materials by the application of protective coatings is gaining popularity these days. In this work, Cr3C2–NiCr coating was deposited on CA6NM turbine steel by the HVOF spray process and studied with regard to its performance under different slurry erosion conditions. The effect of three parameters, namely average particle size of slurry particles, speed (rpm), and slurry concentration on slurry erosion of this coating material, was studied by using a high speed erosion test rig. The analysis of the surfaces of the samples before and after slurry erosion tests was done by using SEM. The HVOF sprayed Cr3C2–NiCr coating showed very good performance under slurry erosion in comparison with uncoated CA6NM steel.

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