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 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%.

Oxidation Properties of NIAI Intermetallic Coatings Prepared by High Velocity Oxy-Fuel Thermal Spraying

1998 ◽  
Author(s):  
J.A. Hearley ◽  
J.A. Little ◽  
A.J. Sturgeon
Keyword(s):  
High Velocity ◽  
Low Carbon Steel ◽  
Thermal Spraying ◽  
Liquid Fuels ◽  
Low Carbon ◽  
Ion Diffusion ◽  
X Ray Diffraction ◽  
Hvof Process ◽  
Diffusion Studies ◽  
Oxidation Properties

Abstract A reaction-formed NiAI intermetallic compound (IMC) powder has been deposited as a coating onto low carbon steel test coupons by the High Velocity Oxy-Fuel (HVOF) process using both gaseous and liquid fuels. The microstructure of this coating has been examined using scanning electron microscopy and x-ray diffraction and was found to depend on spraying conditions. Oxidation tests on the coating in air, between the temperatures of 800°C-1200°C, revealed that an a-alumina (Al2O3) scale formed on the coating's surface. At 1200°C, a nickel spinel (NiO/NiAl2O4) and haematite (Fe2O3) phases were observed. Diffusion studies were performed to calculate an activation energy for iron ion diffusion in NiAl.

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.

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.

Effect of Vanadium and Niobium on Abrasive Behaviour of Arc Sprayed 4Cr13 Coatings

2013 ◽  
Vol 395-396 ◽  
pp. 712-717 ◽  
Author(s):  
Yu Deng ◽  
Sheng Fu Yu ◽  
Ning Yan ◽  
Shu Le Xing ◽  
Lin Bing Huang
Keyword(s):  
High Velocity ◽  
Low Carbon Steel ◽  
Optical Microscope ◽  
Arc Spraying ◽  
Low Carbon ◽  
X Ray Diffraction ◽  
Improve Performance ◽  
Hard Particles ◽  
High Velocity Arc Spraying ◽  
Stainless Steel Coatings

4Cr13 martensitic stainless steel coatings with different amount of V/Nb were prepared on the surface of the Q235 low-carbon steel by high velocity arc spraying (HVAS). The microstructure and properties of the coatings were characterized and tested by scanning electron microscope (SEM), X-ray diffraction (XRD), optical microscope, microhardness tester and wear tester. And the wear mechanisms of the coatings have been studied. The results showed that optimal percentage of V/Nb could improve performance of the coatings. The coatings had good forming properties, uniformity of microstructure and compact structure.The highest value of adhesion strength was up to about 36.80 Mpa. The hard particles could incease the hardness and wear resistanc of the coatings.The average microhardness was about 523 HV0.1, higher than that of 4Cr13 coatings, and the abrasive wear resiatance was enhanced because of the added elements V and Nb. Key words: alloying coatings; 4Cr13; V/Nb; high velocity arc spraying (HVAS); abrasive behaviour

Improvement in wear and corrosion resistance of AISI 1020 steel by high velocity oxy-fuel spray coating containing Ni-Cr-B-Si-Fe-C

2012 ◽  
Vol 31 (2) ◽  
Author(s):  
M. Prince ◽  
A. Justin Thanu ◽  
P. Gopalakrishnan
Keyword(s):  
High Velocity ◽  
Low Carbon Steel ◽  
Base Material ◽  
Spray Coating ◽  
Dry Sliding Wear ◽  
Low Carbon ◽  
X Ray Diffraction ◽  
Wear And Corrosion ◽  
Wear And Corrosion Resistance ◽  
Wear Tests

AbstractIn this investigation, AISI 1020 low carbon steel has been selected as the base material. The Ni based super alloy powder NiCrBSiFeC was sprayed on the base material using high velocity oxy-fuel spraying (HVOF) technique. The thickness of the coating was approximately 0.5 mm (500 μm). The coating was characterized using optical microscopy, Vickers microhardness testing, X-ray diffraction technique and scanning electron microscopy. Dry sliding wear tests were carried out at 3 m

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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