Reducing the mechanical wear of elbows and pipes due to solid particles flow by using nano coating technique (original) (raw)
Related papers
2020
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...
Corrosion Protection of Steel Using Nano Ceramic Particles Coating
In this work, three nanoparticles were used to apply seven different coatings on carbon steel using atomization method (cold spraying) by airbrush to achieve three types of coating. The first is single coatings, including Al2O3, SiC and ZrO2 coatings. The second is binary coatings, including Al2O3 - SiC, Al2O3 - ZrO2 and SiC- ZrO2 coatings. While, the third is Al2O3 - SiC - ZrO2 coating. The characterization of coated surfaces were investigated by AFM and SEM. All these inspections indicated the deposition of nanoparticles on carbon steel surface. The thickness of coated layers were calculated using gravimetric method, while the particle size and roughness were measured from the analysis of atomic force microscopy. The thickness of nanoparticle coatings are 6.22160 μm, 0.0781 μm, 1.5504 μm, 0.5145 μm, 3.469 μm, 1.3680 μm , 2.2152 μm for Al2O3, SiC, ZrO2, Al2O3 - SiC, Al2O3 - ZrO2, SiC- ZrO2, Al2O3 - SiC - ZrO2 respectively. While, the roughness values are 7.0nm, 26.1nm, 5.44nm, 6.86nm, 8.11nm, 6.64nm, 25.2nm for Al2O3, SiC, ZrO2, Al2O3 - SiC, Al2O3 - ZrO2, SiC- ZrO2, Al2O3 - SiC - ZrO2 respectively. Corrosion test was achieved to estimate the corrosion resistance, protection efficiency and porosity percentage. The corrosion potential shifted to more positive value for coated surfaces, and the corrosion current density became lower for coated surfaces. The corrosion rate was decreased.
Influence of Nano-particle on the Wear behaviour of Thin Film Coatings A Review
The current study deals with the friction and wear behaviour of thin film coating used for automotive applications like piston rings, under the influence of nanoparticle like alumina-oxide, copper and many more. The study reports the influence of factors like load and speed under the presence of third body i.e. nano-particle and it has been found that the friction and wear of coatings are determined by adhesion at small load and dominated by adhesion and ploughing at higher load. The shape of particle also affects the wear properties during the test at Pin on disc tribometer. It is found that a small-sized particle can increase the wear of the coating by reducing the friction. These unique tribological mechanisms of the film can help to promote its wide applications in a sand-dust and presence of tiny particle environment.
Experimental Design of Solid Particle Wear Behavior of Ni-Based Composite Coatings
Journal of Composites Science
The composition of nickel-based metal matrix NiCrBSi was varied with 5%, 10% and 15% of Al2O3 particles to obtain high wear resistant coatings by means of a high-velocity oxy fuel (HVOF) thermal spraying process. The coating was characterized by optical microscope, scanning electron microscope (SEM) and X-ray diffractometer (XRD). The physical properties of coatings such as porosity, thickness, surface roughness, surface hardness, fracture toughness, bond strength and density were measured and compared. The experimental design of Taguchi L27 orthogonal array was employed to study and compare the effect of parameters such as impingement angle, impact velocity and alumina per cent in the coating on erosion. The coating containing 15 wt.% of Al2O3 and erodent speed of 33 m/s striking at inclination angle of 30° proved to be the best arrangement in preventing volume loss to a minimum of 0.00015 cc due to low-impact energy, high bond strength and high surface hardness. Analysis of varian...
Solid particle erosion wear on plasma sprayed mild steel and copper surface.pdf
Materials Today, 2018
Structural engineering components in plant made of mild steel and copper are affected by severe erosive wear due to presence of particulates in its surrounding. To protect these costly structural elements, we have taken atmospheric plasma spray process. This process is better for mild steel and copper due to several advance properties such as high temperature stability, coating efficiency, wear and corrosion protection. Coating by this process can be applied onto all suitable base materials with the widest variety of powders. In this investigation we have taken industrial waste like fly-ash, quartz and ilmenite powder as coating composite material and deposited on Mild Steel and Copper substrates with different weight proportions and different power levels of the plasma torch. Erosion type and their mechanism extensively investigated using scanning electron microscopy. Erosion properties have been studied using Air Jet erosion test Reg. with Silica erodent. Two significant parameters i.e. Erosion rate and Avg. microhardness have been measured by varying input i.e. power lever, velocity of erodent and time of erosion exposure. It is observed that, maximum erosion occurs at normal impact angle that indicates about brittle erosion condition . Different graphs are being plotted between mass loss-rate versus time period/impact pressure/impact angle, which gives good correlation with surface features observed. Based on these observations artificial neural network (ANN) models are developed to predict the result in various parameter setup.
Solid particle erosion wear on plasma sprayed mild steel and copper surface
Structural engineering components in plant made of mild steel and copper are affected by severe erosive wear due to presence of particulates in its surrounding. To protect these costly structural elements, we have taken atmospheric plasma spray process. This process is better for mild steel and copper due to several advance properties such as high temperature stability, coating efficiency, wear and corrosion protection. Coating by this process can be applied onto all suitable base materials with the widest variety of powders. In this investigation we have taken industrial waste like fly-ash, quartz and ilmenite powder as coating composite material and deposited on Mild Steel and Copper substrates with different weight proportions and different power levels of the plasma torch. Erosion type and their mechanism extensively investigated using scanning electron microscopy. Erosion properties have been studied using Air Jet erosion test Reg. with Silica erodent. Two significant parameters i.e. Erosion rate and Avg. microhardness have been measured by varying input i.e. power lever, velocity of erodent and time of erosion exposure. It is observed that, maximum erosion occurs at normal impact angle that indicates about brittle erosion condition. Different graphs are being plotted between mass loss-rate versus time period/impact pressure/impact angle, which gives good correlation with surface features observed. Based on these observations artificial neural network (ANN) models are developed to predict the result in various parameter setup.
Solid Particle Erosion Performance of Multilayered Carbide Coatings (WC-SiC-Cr_3C_2
Transdisciplinary Research and Education Center for Green Technologies, Kyushu University, 2023
A modern machine parts such as gas turbine blades and vanes are impacted by high temperature and high speed solid dust particles. As a result may leads to disastrous failure. In order to increase the performance multilayered (WC-SiC-Cr3C2) carbide coating was developed on AISI 304 steel using HVOF process. Erosion test as per ASTM G 76 standard were conducted at differently impingement angle (90, 75, 60, 45 and 30)at room temperature. Micro structural, morphological and element analysis probed using SEM and EDAX. The changes in the resistance to erosion are due to high hardness and less porosity of the developed coating. The analysis showed a well-adhered and dense layer with a uniform distribution and presence of carbides and ability to withstand the erosive effects of solid dust particles.
Solid particle erosion of thermal sprayed coatings
Thermal sprayed coatings are commonly employed to enhance the wear resistance of a wide range of engineering components. Coatings of tungsten carbide based hardmetal, nickel based self-fluxing alloy and composites on the basis of NiCrSiB alloy were deposited from these powder by the detonation gun, continuous detonation spraying, and spray fusion process. Solid particle erosion tests were performed on these coatings with silica abrasives of size in between 0.1 and 0.3 mm. Influence of the test variables and material parameters is discussed. Differences in the wear behavior are rationalized in terms of the coating hardness and structure. Case study of the wear resistance of the coatings in disintegrator mill is proposed.
Estimation the Efficiency of Nano Particles Coating on Carbon Steel by Atomization
In this work, three nanoparticles were applied as coatings on carbon steel using atomization method (cold spraying) by airbrush. The coatings included nano Al 2 O 3 , nano SiC and nano ZrO 2 materials. The characterization of coated surfaces has been investigated by AFM and SEM. All these inspections indicated that the deposition of nanoparticles on carbon steel surface was uniform and homogeneous. The thickness of coated layers was calculated using gravimetric method, while the particle size and roughness were measured from the analysis of atomic force microscopy. With constant conditions of coating, nano alumina coating gave the highest thickness (6.2216 nm) due to agglomeration of these particles compared with others as illustrated in SEM images. Corrosion test was performed to estimate the corrosion resistance, protection efficiency and porosity percentage which indicated the role of nano particle coating on corrosion control. These data showed that the nano alumina was better than other coatings and gave PE 99.69%. Cyclic polarization was also estimated to show the probability of pitting corrosion. The coating with alumina gave the best data for decreasing the chance of pitting corrosion.