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Article
Publication date: 7 August 2018

Yasser Abdelrhman, Ahmed Abouel-Kasem, Karam Emara and Shemy Ahmed

This paper aims to clarify the relationship between the slurry erosion and one of the case hardening treatments, i.e. boronizing in this study, for AISI-5117 steel alloy. AISI-5117

Abstract

Purpose

This paper aims to clarify the relationship between the slurry erosion and one of the case hardening treatments, i.e. boronizing in this study, for AISI-5117 steel alloy. AISI-5117 steel alloy was used because of its variety applications in the field of submarine equipment. Most of the slurry erosion factors such as velocity, impact angle and mechanism of erosion were studied at different impact angles.

Design/methodology/approach

At first, the samples were prepared and subjected to the boronizing treatment in controlled atmosphere. By using a slurry erosion test-rig, all experiments for studying the slurry erosion factors were carried out. Moreover, the studied specimens were investigated via scanning electron microscope, optical microscope and X-ray diffraction to study the erosion mechanism in the different conditions.

Findings

It was expected that the boronization of the AISI-5117 steel would increase its slurry erosion resistance due to its positive impact on the surface hardness. However, the results observed show the opposite, where the boronization of AISI-5117 steel decreased its slurry erosion resistance as implied by the increase of the mass loss percentage at all impact angles.

Originality/value

This research, for the first time, exhibits the effect of boronizing treatment on the slurry erosion in different impact factors accompanied by the erosion mechanism at each impact angle.

Details

Industrial Lubrication and Tribology, vol. 70 no. 7
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 8 May 2018

Mohammed Ahmed Al-Bukhaiti, Ahmed Abouel Kasem Mohamad, Karam Mosa Emara and Shemy M. Ahmed

This paper aims to investigate the influence of slurry concentration on the erosion behavior of AISI 5117 steel and high-chromium white cast iron by using a whirling-arm rig. In…

Abstract

Purpose

This paper aims to investigate the influence of slurry concentration on the erosion behavior of AISI 5117 steel and high-chromium white cast iron by using a whirling-arm rig. In this study, the slurry erosion mechanism with particle concentration has been studied.

Design/methodology/approach

The tests were carried out with particle concentrations in the range of 1-7 Wt.%, and the impact velocity of slurry stream was 15 m/s. Silica sand with a nominal size range of 500-710 µm was used as an erodent. The study revealed that the failure mode was independent of concentration.

Findings

The results showed that the erosion rate decreases with the increase in particle concentration and the variation in the reduction depends on the material. It was found that the variation of fractal dimension calculated from slope of linearized power spectral density of eroded surface image for different concentrations can be used to characterize the slurry erosion intensity in a similar manner to the erosion rate. It was also found that the variation of fractal dimension versus concentration of sand has a general trend that does not depend on magnification factor.

Originality/value

Using the gravitational measurement and image analysis, the variation of the wear with slurry concentration has been analyzed to investigate the implicated mechanisms of erosion during the process.

Details

Industrial Lubrication and Tribology, vol. 70 no. 4
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 12 September 2016

Bahaa Saleh and Ayman A. Aly

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.

Abstract

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.

Details

Industrial Lubrication and Tribology, vol. 68 no. 6
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 20 October 2023

Ergin Kosa and Ali Gökşenli

Erosion and abrasion are the prominent wear mechanisms reducing the lifetime of machine components. Both wear mechanisms are playing a role meanwhile, generating a synergy…

Abstract

Purpose

Erosion and abrasion are the prominent wear mechanisms reducing the lifetime of machine components. Both wear mechanisms are playing a role meanwhile, generating a synergy, leading to a material removal on the target. The purpose of study is to create a mathematical expression for erosive abrasive wear.

Design/methodology/approach

Many factors such as environmental cases and material character have an influence in erosive abrasive wear. In the work, changes in abrasive size and material hardness have been analyzed. As an abrasive particle, quartz sand has been used. All tests have been done in 20 wt.% slurry. Heat treatment has been applied to different steel specimens (steel grades C15, St 37 and Ck45) to change hardness value, which ranged from 185 to 880 Vickers hardness number.

Findings

After the four-hour test, it is determined that by an increase in abrasive size and decrease in material hardness, wear rate increases. Worn surfaces of the targets have been examined to figure out the wear mechanisms at different conditions under scanning electron microscopy. The results indicate that by an increase in material hardness, the number and diameter of micro-craters on the worn surfaces decrease. The diameters of micro-craters have been about 3–8 µm in hard materials and about 120–140 µm in soft materials.

Research limitations/implications

It is determined that by an increase in abrasive size and decrease in material hardness, wear rate increases. The results indicate that by an increase in material hardness, the number and diameter of micro-craters on the worn surfaces decrease.

Practical implications

The study enables to indicate the dominant factor in worn steel used in mechanical components.

Originality/value

After analyzing the test results, a novel mathematical expression, considering both abrasive size and material hardness, has been developed.

Details

Multidiscipline Modeling in Materials and Structures, vol. 19 no. 6
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 10 June 2021

Jashanpreet Singh

The purpose of this paper is to carry out erosion wear investigation on high-velocity oxy-fuel (HVOF)-deposited 86WC-10Co4Cr and synergistic Ni/Chromia powder (i.e. 80Ni-20Cr2O3

Abstract

Purpose

The purpose of this paper is to carry out erosion wear investigation on high-velocity oxy-fuel (HVOF)-deposited 86WC-10Co4Cr and synergistic Ni/Chromia powder (i.e. 80Ni-20Cr2O3) on AISI 316L.

Design/methodology/approach

Design of experiments-artificial neural network (DOE-ANN) methodology was adopted to calculate the erosion wear. Taguchi’s orthogonal array L16 (42) was used to perform set-of-erosion experiments followed by lower-the-better rule. The artificial neural network (ANN) model is used on erosion wear data obtained from the experiments.

Findings

Experimental results indicate that 86WC-10Co4Cr provided better erosion wear resistance as compared to Ni/Chromia. The erosion wear of 86WC-10Co4Cr and synergistic Ni/Chromia coatings increases with an increase in time duration, solid concentration and time. The magnitude of erosion generated by ashes was comparatively lower than sand. The arithmetic mean roughness (Ra) of finished AISI 316L, 86WC-10Co4Cr and Ni/Chromia coating was found as 0.46 ± 0.13, 6.50 ± 0.16 and 7.04 ± 0.23 µm, respectively. Surface microhardness of AISI 316L, 86WC-10Co4Cr and Ni/Chromia coating was found as 197 ± 18, 1,156 ± 18 and 1,021± 21 HV, respectively.

Practical implications

The present results can be useful for estimation of erosion wear in slurry pumps used in mining industry for the conveying of sand and in thermal power plants for the conveying of ashes to the dyke area.

Originality/value

The erosion wear of HVOF-sprayed 86WC-10Co4Cr and Synergistic Ni/Chromia powders was studied experimentally as well as predicted by the ANN model, and wear mechanisms are well discussed by scanning electron micrographs.

Details

Industrial Lubrication and Tribology, vol. 73 no. 5
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 25 September 2018

Kaushal Kumar, Satish Kumar, Munish Gupta and Hem Chander Garg

This paper aims at erosion wear experimentation conducted on two piping materials, namely SS202 and SS304 to establish the effect of rotational speed, concentration and time…

Abstract

Purpose

This paper aims at erosion wear experimentation conducted on two piping materials, namely SS202 and SS304 to establish the effect of rotational speed, concentration and time period.

Design/methodology/approach

Erosion wear because of slurry flow is investigated using a slurry erosion pot tester. Fly ash is taken as erodent material having different solid concentrations lie in range 30 to 60per cent (by weight). Experiments are performed at four different speeds, i.e. 600; 900; 1,200; and 1,500 rpm for time duration of 90, 120, 150 and 180 min, respectively. To enhance erosion wear resistance of both piping materials, high-velocity-oxy-fuel coating technique is used to deposit WC-10Co4Cr coating. The parametric influence of erosion wear is optimized using Taguchi method.

Findings

The results show that significant improvement in erosion wear resistance is observed by deposition of WC-10Co4Cr coating. It is observed that rotational speed is found as highly influencing parameter followed by concentration and time duration. Parametric investigation of erosion wear is helpful to develop a procedure for minimizing the erosion wear in pipeline for the flow of solid-liquid mixture.

Originality/value

Slurry erosion wear of WC-10Co4Cr coated stainless steel (SS202 and SS304) is substantiated by extensive microstructural analysis and optimization technique.

Details

Industrial Lubrication and Tribology, vol. 70 no. 9
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 16 June 2021

Jashanpreet Singh and Jatinder Pal Singh

This study aims to deal with development and performance analysis of high-velocity oxy-fuel (HVOF) thermally sprayed Mo2C-based WC-CoCr (tungsten carbine cobalt chrome) (Co-10…

Abstract

Purpose

This study aims to deal with development and performance analysis of high-velocity oxy-fuel (HVOF) thermally sprayed Mo2C-based WC-CoCr (tungsten carbine cobalt chrome) (Co-10% and Cr-4%) cermet coating deposited on the pump impeller steel 316 L.

Design/methodology/approach

In this work, a study was carried out by modifying the conventional WC-CoCr powder with a small addition of molybdenum carbide (Mo2C). Reinforcement was done by 1–4 wt.% addition of Mo2C feedstocks in WC-CoCr powder by using a jar ball mill process. The design of experiment was implemented for optimization of the percentage of Mo2C feedstock. L16 (4 × 4) orthogonal array was used to design the experiments for erosion output for the input parameters namely velocity, particle size, concentration and Mo2C proportion.

Findings

Results show that the Mo2C-based WC-CoCr coating provides better microhardness as compared to conventional WC-CoCr coating. The present study also reveals that the deposition of conventional WC-CoCr coating has improved the wear resistance of SS 316 L by 9.98%. However, the slurry erosion performance of conventional WC-CoCr coating was improved as 69.6% by the addition of 3% Mo2C.

Practical implications

WC-CoCr coatings are universally used for protecting the equipment and machinery from abrasion, erosion and corrosion. So, the 3% Mo2C-based WC-CoCr can be useful in power plants and various industries like mining, chemical, automobile, cementing and food processing industries.

Originality/value

A new HVOF coating has been developed by the addition of Mo2C feedstock in WC-CoCr powder (Co 10% and Cr 4%) and the percentage of Mo2C feedstock was optimized to improve the tribological behavior of WC-CoCr coating.

Details

Industrial Lubrication and Tribology, vol. 74 no. 4
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 8 July 2019

Jashanpreet Singh

The purpose of this study is to analyze the slurry erosion failure of Ni-20Cr (Ni-Cr2O3), Ni-20Al (Ni-Al2O3) and Al-20Ti (Al2O3-TiO2) coatings deposited on SS316L by the…

123

Abstract

Purpose

The purpose of this study is to analyze the slurry erosion failure of Ni-20Cr (Ni-Cr2O3), Ni-20Al (Ni-Al2O3) and Al-20Ti (Al2O3-TiO2) coatings deposited on SS316L by the high-velocity oxy-fuel process.

Design/methodology/approach

Slurry erosion experiments were conducted using a pot type erosion tester at different velocities 1.81, 2.71, 3.61 and 4.59 m/s for the time duration of 90-180 minutes. Fly ash and bottom ash were used as erodent media; the concentration of mass flux was taken as 30-60 wt. per cent. Artificial neural network (ANN) method was used to simulate the slurry erosion for thermally sprayed coatings.

Findings

Slurry erosion of coatings increases non-linearly with an increase in experimental durations, mass flux and velocity. Slurry erosion of Ni-20Cr and Ni-20Al layers was found to be maximum at 60° impingement angle, whereas 30° for SS316L and 45° for Al-20Ti coating. Slurry erosion performance of SS316L was improved by 2.56-3.19 times by depositing Ni-20Cr and Ni-20Al layers, whereas it improved 1.15-1.75 times by Al-20Ti coating. The slurry erosion SS316L was found almost 1.35 ± 1.28 times greater than that of the Ni-20Al coating, whereas it was to be 1.12 ± 1.36 times greater than Al-20Ti. Ni-20Al-coated SS316L showed a lower value of slurry erosion than Al-20Ti-coated SS316L.

Practical implications

Stainless Steel SS316L is widely used in hydraulic machinery (such as turbines, pumps, valves, fittings, etc.) of hydraulic and thermal power plants, chemical industry and marine industry. Therefore, the deposition of ductile and brittle coatings is a better option for their durable performance.

Originality/value

Erosion wear of Ni-20Cr, Ni-20Al and Al-20Ti coatings was successfully simulated by using an artificial neural network model by supplying experimental data as a target.

Details

Industrial Lubrication and Tribology, vol. 71 no. 7
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 22 October 2018

Ali Mohammad Rashidi, Mehrad Paknezhad and Tooraj Yousefi

This study aims to clarify the relationship between inclination angle of hot surface of CPU and its temperature in absence and presence of aluminum foam as a cooling system. It…

Abstract

Purpose

This study aims to clarify the relationship between inclination angle of hot surface of CPU and its temperature in absence and presence of aluminum foam as a cooling system. It proposes application of the artificial neural [multi-layer perceptron (MLP) and radial basis function] networks and adaptive neuron-fuzzy inference system (ANFIS) to predict interface temperature of central processing unit (CPU)/metal foam heat sink.

Design/methodology/approach

To provide a consistent set of data, the surface of an aluminum cone with and without installing Duocel aluminum foam was heated in a natural convection using an electrical resistor. The hot surface temperature was measured using five K-type thermocouples (±0.1°C). To develop the predictive models, ambient temperature, input power and inclination angle are taken as input which varied from 23°C to 32°C, 4 to 20 W and 0° to 90°, respectively. The hot surface temperature is taken as the output.

Findings

The results show that in the presence of foam, the hot surface temperature was less sensitive to the variations of angle, and the maximum enhancement of the heat transfer coefficient was 23 per cent at the vertical position. Both MLP network and ANFIS are comparable, but the values predicted by MLP network are in more conformity with the measured values.

Originality/value

The effect of metal foam on the inclination angle/hot surface temperature dependence is identified. The optimum angle is clarified. The applicability of the MLP networks to predict interface temperature of CPU/heat sink is approved.

Details

International Journal of Numerical Methods for Heat & Fluid Flow, vol. 28 no. 12
Type: Research Article
ISSN: 0961-5539

Keywords

Article
Publication date: 5 June 2020

Nenzi Wang and Chih-Ming Tsai

In this study, artificial neural networks (ANNs) are constructed and validated by using the bearing data generated numerically from a thermohydrodynamic (THD) lubrication model…

Abstract

Purpose

In this study, artificial neural networks (ANNs) are constructed and validated by using the bearing data generated numerically from a thermohydrodynamic (THD) lubrication model. In many tribological simulations, a surrogate model (meta-model) for obtaining a fast solution with sufficient accuracy is highly desired.

Design/methodology/approach

The THD model is represented by two coupled partial differential equations, a simplified generalized Reynolds equation, considering the viscosity variation across the film thickness direction and a transient energy equation for the 3-D film temperature distribution. The ANNs tested are having a single- or dual-hidden-layer with two inputs and one output. The root-mean-square error and maximum/minimum absolute errors of validation points, when comparing with the THD solutions, were used to evaluate the prediction accuracy of the ANNs.

Findings

It is demonstrated that a properly constructed ANN surrogate model can predict the THD lubrication performance almost instantly with accuracy adequately retained.

Originality/value

This study extends the use of ANNs to the applications other than the analyses dealing with experimental data. A similar procedure can be used to build a surrogate model for computationally intensive tribological models to have fast results. One of such applications is conducting extensive optimum design of tribological components or systems.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2020-0109/

Details

Industrial Lubrication and Tribology, vol. 72 no. 10
Type: Research Article
ISSN: 0036-8792

Keywords

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