Experimental analysis of aluminum alloy under solid particle erosion process

2016 ◽  
Vol 230 (12) ◽  
pp. 1516-1541 ◽  
Author(s):  
Mohammad A Chowdhury ◽  
Uttam K Debnath ◽  
Dewan M Nuruzzaman ◽  
Md. Monirul Islam
Keyword(s):  
Aluminum Alloy ◽  
Impact Velocity ◽  
Operating Parameter ◽  
Maximum Level ◽  
Impact Angle ◽  
Silica Sand ◽  
Erosion Process ◽  
Damage Propagation ◽  
Erosion Efficiency ◽  
The Impact

The erosion behaviors of aluminum alloy have been evaluated practically at different test conditions under ambient temperature. Irregular silica sand (SiO2) is used as an erodent within the range of 300–600 µm. The impact velocity within 30–50 m/s, impact angle 15–90°, and stand-off distance 15–25 mm considered as related parameters. The maximum level of erosion is obtained at impact angle 15° which indicates the ductile manner of the tested alloy. The higher the impact velocity, the higher the erosion rate as almost linear fashion is observed. Mass loss of aluminum alloy reduces with the increase of stand-off distance. A dimensional analysis, erosion efficiency (η) and relationship between friction and erosion indicate the prominent correlation. The test results are designated using Taguchi’s concept to ensure the minimization of observations for clarification of results in alternative process. ANOVA data analysis is considered to signify the interaction of tested parameters as well as identifying most influencing operating parameter. S/N ratio indicates that there are 2.92% deviations estimated between predicted and experimental results. To elaborately analyze the results, GMDH method is mentioned. After erosion process of the tested composite, the damage propagation on the surfaces is examined using SEM for confirming wear mechanisms. The elemental composition of eroded test samples at varying percentage of aluminum is analyzed by energy dispersive X-ray spectroscopy analysis.

scholarly journals Experimental Evaluation of Erosion of Gunmetal under Asymmetrical Shaped Sand Particle

2015 ◽  
Vol 2015 ◽  
pp. 1-31 ◽  
Author(s):  
Mohammad Asaduzzaman Chowdhury ◽  
Uttam Kumar Debnath ◽  
Dewan Muhammad Nuruzzaman ◽  
Md. Monirul Islam
Keyword(s):  
Impact Velocity ◽  
Wear Behavior ◽  
Maximum Level ◽  
Impact Angle ◽  
Operating Conditions ◽  
Silica Sand ◽  
Sand Particle ◽  
Damage Propagation ◽  
Erosion Efficiency ◽  
The Impact

The erosion characteristics of gunmetal have been evaluated practically at different operating conditions. Asymmetrical silica sand (SiO2) is taken into account as erodent within range of 300–600 μm. The impact velocity within 30–50 m/sec, impact angle 15–900, and stand off distance 15–25 mm are inspected as other relevant operating test conditions. The maximum level of erosion is obtained at impact angle 15° which indicates the ductile manner of the tested gunmetal. The higher the impact velocity, the higher the erosion rate as almost linear fashion is observed. Mass loss of gunmetal reduces with the increase of stand-off distance. A dimensional analysis, erosion efficiency (η), and relationship between friction and erosion indicate the prominent correlation. The test results are designated using Taguchi’s and ANOVA concept.S/Nratio indicates that there are 1.72% deviations that are estimated between predicted and experimental results. To elaborately analyze the results, ANN and GMDH methods are mentioned. After erosion process of tested composite, the damage propagation on surfaces is examined using SEM for the confirmation of possible nature of wear behavior. The elemental composition of eroded test samples at varying percentage of gunmetal is analyzed by EDX analysis.

Stepwise Erosion as a Method for Investigating the Wear Mechanisms at Different Impact Angles in Slurry Erosion

2014 ◽  
Vol 136 (2) ◽  
Author(s):  
Y. M. Abd-Elrhman ◽  
A. Abouel-Kasem ◽  
S. M. Ahmed ◽  
K. M. Emara
Keyword(s):  
Rebound Effect ◽  
Impact Angle ◽  
Silica Sand ◽  
Slurry Erosion ◽  
Nominal Size ◽  
Erosion Mechanisms ◽  
Impact Angles ◽  
The Impact ◽  
Calculated Number ◽  
Number Of Particles

In the present work, stepwise erosion technique was carried out to investigate in detail the influence of impact angle on the erosion process of AISI 5117 steel. The number of impact sites and their morphologies at different impact angles were investigated using scanning electron microscope (SEM) examination and image analysis. The tests were carried out with particle concentration of 1 wt. %, and the impact velocity of slurry stream was 15 m/s. Silica sand—which has a nominal size range of 250–355 μm—was used as an erodent, using whirling-arm test rig. The results have shown that the number of craters, as expected, increases with the increase in the mass of erodent for all impact angles and this number decreases with the increase of the impact angle. In addition, the counted number of craters is larger than the calculated number of particles at any stage for all impact angles. This may be explained by the effect of the rebound effect of particles, the irregular shape for these particles, and particle fragmentation. The effect of impact angle based on the impact crater shape can be divided into two regions; the first region for θ ≤ 60 deg and the second region for θ ≥ 75 deg. The shape of the craters is related to the dominant erosion mechanisms of plowing and microcutting in the first region and indentation and lip extrusion in the second region. In the first region, the length of the tracks decreases with the increase of impact angle. The calculated size ranges are from few micrometers to 100 μm for the first region and to 50 μm in the second region. Chipping of the former impact sites by subsequent impact particles plays an important role in developing erosion.

Numerical Analysis of Wavy Interface Formation and Successive Temperature Change in Magnetic Pulse Welded Al/Cu Joint

2016 ◽  
Vol 877 ◽  
pp. 655-661 ◽  
Author(s):  
Junto Nishiwaki ◽  
Takashi Kambe ◽  
Yasutaka Kedo ◽  
Yohei Harada ◽  
Shinji Muraishi ◽  
...  
Keyword(s):  
Impact Velocity ◽  
Intermediate Layer ◽  
Impact Angle ◽  
Joint Interface ◽  
Dissimilar Metals ◽  
Magnetic Pulse ◽  
Flyer Plate ◽  
Interface Formation ◽  
Wavy Interface ◽  
The Impact

Magnetic pulse welding (MPW) which is one of the impact welding methods is suitable for a wide variety of combinations of similar and dissimilar metals. The flyer plate is accelerated by electromagnetic force and collided to the parent plate. A characteristic wavy interface is formed. The impact velocity and impact angle of the flyer plate during impact are important parameters which affect the interface morphology. In the case of dissimilar metals (e.g. Al/Cu, Al/Fe), the intermediate layer (such as intermetallic compound (IMC)) is formed by wavy interface formation and local temperature increase. The intermediate layer often decreases the bonding strength. Wavy interface formation mechanism and temperature increase at the joint interface should be investigated in order to obtain the dissimilar metal joint with high bonding strength. In this study, the impact velocity and impact angle of the flyer plate were obtained by using ANSYS Emag-Mechanical. Based on the obtained impact velocity and impact angle of the flyer plate in the MPW, the wavy interface formation and temperature change were reproduced by using ANSYS Autodyn for solving non-liner dynamics problems. Al sheets and Cu sheets were joined by the MPW. The joint interface was observed by OM and SEM and compared to the simulation result.

Design and Performance of Slurry Erosion Tester

2010 ◽  
Vol 132 (2) ◽  
Author(s):  
A. Abouel-Kasem ◽  
Y. M. Abd-elrhman ◽  
K. M. Emara ◽  
S. M. Ahmed
Keyword(s):  
Impact Velocity ◽  
Erosion Rate ◽  
Sample Surface ◽  
Erosion Process ◽  
Impingement Angle ◽  
Slurry Erosion ◽  
Erosion Test ◽  
And Performance ◽  
Paint Removal ◽  
The Impact

A slurry whirling arm erosion test ring was constructed and a series of erosion tests and post-erosion analysis were carried out using a paint erosion indication technique. The pattern of the paint removal presented a highly visual and accelerated map for the erosion process and its behavior. Also, the erosion rate of paint removal was investigated under a number of erosion variables. It was observed that the rebounding of the erodent particles from the sample surface play an important role in developing erosion for this tester. The erosion pattern showed that the effect of the rebound particles depends on the impact velocity and impingement angle. It was also observed that the erosion behavior of paint as a function of impingement angle, impact velocity, and erosion time was similar to that reported in literature for engineering materials. The slurry whirling arm erosion tester seems to be promising for simulating the slurry process in real cases.

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

2017 ◽  
Vol 139 (4) ◽  
Author(s):  
M. A. Al-Bukhaiti ◽  
A. Abouel-Kasem ◽  
K. M. Emara ◽  
S. M. Ahmed
Keyword(s):  
Impact Velocity ◽  
Erosion Resistance ◽  
Normal Incidence ◽  
Impact Angle ◽  
Silica Sand ◽  
Slurry Erosion ◽  
High Chromium ◽  
Nominal Size ◽  
Plastic Indentation ◽  
Erosion Mechanisms

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.

Erosion and its Effect on a Water-Cooled Turbine

1978 ◽  
Author(s):  
Max Freedman
Keyword(s):  
Impact Velocity ◽  
Gas Turbines ◽  
Mass Loss Rate ◽  
Impact Angle ◽  
Aluminum Specimen ◽  
High Impact Velocity ◽  
Short Time ◽  
Impact Angles ◽  
The Impact

Erosion tests were run to obtain data for designing a water-cooled gas turbine collection shroud. All tests utilized a coherent stream of water ejected from a static nozzle against stationary small block specimens. Twenty-one tests were run with aluminum specimens and 16 more tests with other materials. The impact velocity was varied from 165 to 270 m/s (540 to 890 fps). The impact angle was varied from 10 to 90 deg. The mass loss rate results generally show four erosion regions, which are consistent with the literature. A correlation between regions two and four was found. Aluminum specimen erosion rate was found to be unexpectedly high with impact angles of 10 deg and moderate-to-high impact velocity. No report of previous liquid erosion work at impact angles less than 30 deg was found; since it is expected that water-cooled gas turbines will operate at impact angles of about 15 deg, erosion in this low impact angle region should be studied. If the correlation between erosion regions two and four can be quantized, then very short-time tests could be used to predict long-term erosion at minimal cost.

Evaluating Impact Properties of Cement Clinker at Different Angle for Impact Indentation

2011 ◽  
Vol 492 ◽  
pp. 43-46
Author(s):  
Xiu Fang Wang ◽  
Yi Wang Bao ◽  
Yan Qiu ◽  
Xiao Gen Liu ◽  
Yuan Tian
Keyword(s):  
Impact Velocity ◽  
Impact Force ◽  
Surface Damage ◽  
Impact Angle ◽  
Cement Clinker ◽  
Damage Degree ◽  
Indentation Tests ◽  
Impact Angles ◽  
The Impact ◽  
Peak Impact Force

Spherical impact indentation tests with different impact angles (90°, 60°, 45°, and 30°) was carried out to understand the effect of impact angles on damage degree of cement clinker. A linear rail which can adjust angle to alter impact velocity was used to guide the slipping impact head to impact the sample. The different steel wedge was used to change the impact angle. It is found that the area of damage surface for cement clinker is most serious the peak impact force for surface damage decreases but the contact indentation becomes longer with decreasing impact angle when the impact angle is 45°. Under almost the same impact velocity, the smaller the impact angle, the higher the impulse, the longer contact time, and the peak impact force of 45° is maximum.

scholarly journals An Experimental Study on the Oblique Collisions of Water Droplets With a Smooth Hot Solid

2012 ◽  
Vol 134 (7) ◽  
Author(s):  
Hitoshi Fujimoto ◽  
Ryota Doi ◽  
Hirohiko Takuda
Keyword(s):  
Surface Temperature ◽  
Impact Velocity ◽  
Solid Surface ◽  
Impact Angle ◽  
Alloy Surface ◽  
Inconel 625 ◽  
Normal Velocity ◽  
Inconel 625 Alloy ◽  
Secondary Droplets ◽  
The Impact

The motions of liquid droplets impinging on a solid substrate have been studied experimentally in fundamental research on various types of industrial applications, including spray cooling. The oblique collision of a single water droplet with a hot Inconel 625 alloy surface has been investigated by means of a two-directional flash photography technique that uses two digital still cameras and three flash units. The experiments were conducted under the following conditions. The preimpact diameter of the droplets was approximately 0.6 mm, the impact velocity was 1.9–3.1 m/s, and the temperature of the Inconel 625 alloy surface ranged from 170 °C to 500 °C. The impact angle of droplets on the solid surface was in the range 45 deg–90 deg. Experiments using 2.5 mm diameter droplets at an impact velocity of 0.84–1.4 m/s were also conducted at the surface temperature of 500 °C. At surface temperatures of 200 °C, 300 °C, and 400 °C, the droplet deforms into an asymmetric shape and moves downward along the tilted surface. Numerous secondary droplets jet upward from the deforming droplet as a result of the blowout of vapor bubbles into the atmosphere. At a surface temperature of 500 °C and a low Weber number Wen based on the normal velocity component to the solid surface, no secondary droplets are observed. The droplet rebounds off the solid without disintegrating. The droplet becomes almost axisymmetric in shape during the collision regardless of the impact angle. The dimensionless collision behaviors of large and small droplets were similar for the same Wen when the temperature was 500 °C. Using Wen, we investigated the deformation characteristics of droplets in oblique collisions.

Optimization of erosion wears of Al–Mg–Si–Cu–SiC composite produced by the PM method

2020 ◽  
Vol 39 (1) ◽  
pp. 63-75
Author(s):  
Rajesh Kumar Behera ◽  
Birajendu Prasad Samal ◽  
Sarat Chandra Panigrahi ◽  
Sudhansu Ranjan Das
Keyword(s):  
Design Of Experiments ◽  
Impact Velocity ◽  
Metal Matrix ◽  
Erosion Rate ◽  
Desirability Function ◽  
Impact Angle ◽  
Experimental Results ◽  
Function Approach ◽  
The Impact ◽  
Desirability Function Approach

Abstract Metal matrix composites are expanding their range every day due to their various industrial applications in manufacturing sectors, to attain high performance and favorable characteristics such as light weight, more excellent corrosion as well as wear resistance, high specific strength and high temperature-resistance than conventional materials. This study deals with analysis on erosion wear characteristic and corrosion behavior of newly-engineered aluminum metal–matrix composite (Al–0.5Si–0.5Mg–2.5Cu–5SiC) developed by powder metallurgy method. Solid particle erosion test was conducted on the newly developed AMMC product and the execution of design of experiments through Taguchi and statistical techniques demonstrates the feasibility of investigating the erosion characterization and behaviors of the composites. Sixteen set of experimental trials were performed by considering three process parameters (impact angle, stand-off distance, and impact velocity) associated with four levels each. Experimental results in accordance of Taguchi’s orthogonal array design of experiments are analyzed by employing analysis of variance (ANOVA), response surface methodology (RSM) and desirability function approach for analysis, predictive modeling and optimization of erosion rate, respectively. Thereafter, an observation on eroded surface morphology is performed under the influence of impact velocity by employing scanning electron microscope (SEM) to entrench the process. Result shows that, the impact velocity followed by impact angle have significant contribution (80.42 and 8.71%, respectively) in improvement of erosion rate. The methodology proposed in this study collects the experimental results and builds a mathematical model in the domain of interest and optimized the process model. Under the highest desirability (1), desirability-function approach of RSM presented the optimal manufacturing conditions at impact velocity of 18 m/s, stand-off distance of 26 mm and impact angle of 67° with estimated erosion rate of 65.155 mg/kg. The experimental data generated for Al–0.5Si–0.5Mg–2.5Cu–5SiC AMMC will be useful for the industry.

scholarly journals Numerical Simulations of Air Cavities in Inclined Plunging Jets

2020 ◽  
Vol 2020 ◽  
pp. 1-15
Author(s):  
Qian Sun ◽  
Hao Yuan ◽  
Lei Jiang ◽  
Guangxiang Xu ◽  
Xujin Zhang
Keyword(s):  
Numerical Simulations ◽  
Impact Velocity ◽  
Dynamic Process ◽  
Impact Angle ◽  
Empirical Formulas ◽  
Water Jets ◽  
Inclination Angles ◽  
Air Cavities ◽  
The Impact ◽  
Penetration Velocity

The dynamic process of circular water jets plunging into a quiescent pool was analyzed in this study based on the RNG k∼ε turbulence model and VOF method. The effects of jet velocity and inclination angles relative to horizontal on the cavity shapes and sizes were analyzed. The simulation successfully captured the formation, development, pinch-off, and disintegration phenomena of cavities. The shape of the cavity is mainly affected by the impact angle, while the impact velocity mainly affects the size of the cavity. The cavity pinch-off initially appears at a certain point in any direction for vertical jets, while the cavity in the opposite direction of flow pinch-off appears before the cavity in the direction of flow for inclined jets. Before cavity pinch-off, the maximum radial and axial sizes of the cavity generally increase with the impact velocity and the time after impingement. The axial penetration velocity of the cavity tip is approximately half of the impact velocity, which is consistent with previous research. Finally, based on the statistics of the cavity sizes, empirical formulas for predicting the maximum radial and axial sizes of the cavity were established.

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