Study on Erosion Response of Hybrid Composites Using Taguchi Experimental Design

This paper describes the development of multiphase hybrid composites consisting of polyester reinforced with E-glass fiber and ceramic particulates. It further investigates the erosion wear response of these composites and presents a comparison of the influence of three different particulate fillers—fly ash, alumina (Al2O3), and silicon carbide (SiC)—on the wear characteristics of glass-polyester composites. For this purpose, the erosion test schedule in an air jet type test rig is made, following design of experiments approach using Taguchi’s orthogonal arrays. The Taguchi approach enables us to determine optimal parameter settings that lead to minimization of the erosion rate. The results indicate that erodent size, filler content, impingement angle, and impact velocity influence the wear rate significantly. The experimental results are in good agreement with the values from the theoretical model. An artificial neural network approach is also applied to predict the wear rate of the composites and compared with the theoretical results. This study reveals that addition of hard particulate fillers such as fly ash, Al2O3, and SiC improves the erosion resistance of glass-polyester composites significantly. An industrial waste such as fly ash exhibits better filler characteristics compared with those of alumina and SiC. Finally, a popular evolutionary approach known as genetic algorithm is used to generalize the method of finding out optimal factor settings for minimum wear rate.

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High-Temperature Erosive Wear Behavior of High-Velocity Oxy-Fuel Sprayed Cr3C225 (Ni20Cr) Coating on (AISI 316) Austenitic Steel

Journal of Tribology ◽

10.1115/1.4046290 ◽

2020 ◽

Vol 142 (7) ◽

Cited By ~ 1

Author(s):

Hemant Nautiyal ◽

Pankaj Kumar Sharma ◽

Rajnesh Tyagi

Keyword(s):

High Temperature ◽

Fly Ash ◽

Wear Rate ◽

Austenitic Steel ◽

High Velocity ◽

Wear Behavior ◽

Air Jet ◽

Coated Surface ◽

Aisi 316 ◽

Impact Angles

Abstract AISI 316 austenitic steel is extensively used in various components of power plants like boilers, boiler tubes and pipes, which suffer severe air jet erosion. Fly ash is a major erodent in that case. Present study is conducted to study the effect of Cr3C225 (Ni20Cr) coating on 316 substrates, when it is exposed to thermal power plant erosive conditions. High-velocity oxy-fuel deposition technique is used for coating. Major constituent of Indian fly ash is alumina, so alumina particles are taken as erodent. Erosion wear behavior is investigated for coated and uncoated conditions using an air jet erosion tester at 100 m/s impact velocity. Three impact angles, i.e., 30 deg, 60 deg, and 90 deg, and four working temperatures, room temperature, 200 °C, 400 °C, and 600 °C, were chosen to identify wear mechanism. Scanning electron microscopy and energy dispersive X-ray spectroscopy (EDX) were utilized to characterize the coated, uncoated, and eroded surface. Erosion behavior is correlated with micro hardness, roughness, and microstructure. Results reveal that the coated surface offers better erosion resistance than the uncoated surface. Substrate exhibits ductile wear behavior as it shows higher wear rate at low angle and decreases on increasing the impact angle, while coating offers good wear characteristics at 30 deg and 90 deg impact angles. An increase in working temperature favors wear rate increment for both coated and uncoated samples. However, coated samples exhibit ductile erosive behavior at high temperatures. Uncoated surfaces have micro-cutting and deformation as major erosive mechanisms. Whereas for coated samples at high temperature, oxide layer formation takes place and erosion takes place due to spalling of the oxides from the coated surface.

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Erosion Wear Characteristics on Aroma Skin and Biochar Filled Polyester Composites

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.b1067.1292s219 ◽

2019 ◽

Vol 9 (2S2) ◽

pp. 399-402

Keyword(s):

Wear Rate ◽

Impact Velocity ◽

Discharge Rate ◽

Matrix Material ◽

Composite Plates ◽

Erosion Wear ◽

Impingement Angle ◽

Air Jet ◽

Erosion Behaviour ◽

Polyester Composites

This work focused on erosion behaviour of pure polyester, aroma skin (5wt%) and biochar (7.5wt%) reinforced polyester composites. The hand-layup method is used to develop the composite plate. To investigate the erosion wear rate of the developed composite plates, the sized specimen is subjected to erosion studies. As per ASTM G76 the erosion test was done with the help of air jet erosion tester. To study the parameters of different reinforcement, impingement angle and impact velocity of the fabricated specimen. The erosion behaviour of particulate reinforced polyester composites is evaluated at two different reinforcement (aroma skin and biochar) and three different wt% (0wt%, 5wt% and 7.5wt%) at varying impingement angles (30o , 45o , 60o and 75o ) for regular time intervals. The standoff distance, impact velocity and erodent discharge rate were kept constant. Alumina oxide is used as erodent material with the size of 50µm. From the result, it is observed that increase in impingement angle increase the erosion rates. Another observation is made that addition of reinforcement in matrix material also shows increase in wear rate of composite. In comparison of both aroma skin and biochar reinforced polymer composites, biochar enhances the erosion resistance of composite in all impingement angles.

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Effect of SiC/Fly Ash Reinforcement on Surface Properties of Aluminum 7075 Hybrid Composites

Coatings ◽

10.3390/coatings10060541 ◽

2020 ◽

Vol 10 (6) ◽

pp. 541 ◽

Cited By ~ 1

Author(s):

Namdev Ashok Patil ◽

Srinivasa Rao Pedapati ◽

Othman Bin Mamat ◽

Abdul Munir Hidayat Syah Lubis

Keyword(s):

Fly Ash ◽

Wear Rate ◽

Surface Properties ◽

Hybrid Composites ◽

Dry Sliding ◽

Al Alloy ◽

Volume Percentage ◽

Wear Rates ◽

Friction Stir ◽

Aluminum 7075

Friction stir processing (FSP) has emerged as a valuable technique in the surface metal matrix composite fabrication field. In this process, solid-state processing mostly avoids the formation of detrimental phases inside composites. Despite having a high specific strength, further extensive Al alloy applications are limited due to their poor surface properties. A hybrid reinforcement approach can be used to improve surface properties. In this study, industrial waste fly ash material is mixed with hard SiC ceramic particles. The main focus of this research is to improve wear resistance under dry sliding conditions and microhardness of aluminum 7075-T651 by dispersion of silicon carbide-fly ash (SiC/fly ash) powder in a base alloy by FSP. The parameters used for this investigation are: tool rotation rpm (500, 1000 and 1500), the tool traverse mm/min (20, 30 and 40), the reinforcement’s hybrid ratio HR (60:40, 75:25 and 90:10) and the volume percentage vol.% (4%, 8% and 12%). The influence of these parameters on the resultant composite’s microstructure, dry sliding wear rate and micro-hardness was studied. By using response surface methodology (RSM), desirable ranges of process parameters for lower wear rate and higher microhardness were obtained. The interaction effect of SiC/fly ash volume percentage and hybrid ratio had the most influential effect on the wear rates, as well as microhardness of composites. Moreover, microhardness increased with an increase in the volume percentage of SiC/fly ash powders towards high SiC content in hybrid ratio. Interestingly, among stirring parameters, tool traverse speed was found to be more influential than tool rotational speed. The minimum wear rate was observed for the Run 20 sample (w: 1000 rpm, v: 40 mm/min, HR: 75:25, vol.%: 8). A maximum microhardness of 241.20 HV was achieved for Run 15 (w: 500 rpm, v: 40 mm/min, HR: 90:10, vol.%: 12) sample. Mainly, reinforcement distribution—in accordance with the stirring action generated by the tool—had a major role in controlling the surface properties of the resultant composites.

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