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This paper aims to cover all the aspects of development, investigation and analysis phases to evaluate the slurry erosion performance of test coatings. The powders having composition of Ni-20Al₂O₃ and Ni-15Al2O₃-5TiO₂ were deposited on CA6NM grade turbine steel by using high velocity flame spray (HVFS) technique. The characterization of the coatings was done with the help of SEM/EDS and XRD techniques. Various properties such as micro-hardness and bonding strength of the coatings were also evaluated. Thereafter, these coatings were subjected to an indigenously developed high speed slurry erosion tester at different levels of rotational speed, erodent particle size and slurry concentration. The effect of these parameters on the erosion behavior of coatings was also evaluated. The slurry erosion tests and SEM of the eroded surfaces revealed remarkable improvement in slurry erosion resistance of Ni-15Al₂O₃-5TiO₂ coating in comparison with Ni-20Al₂O₃ coating.

Two different compositions of HVFS coating were developed onto CA6NM steel. Subsequently, these coatings were evaluated by means of mechanical and microstructural characterization. Further, slurry erosion testing was done to analyze the erosive wear behavior of developed coatings.

The coatings were successfully developed by HVFS process. Cross-sectional microscopic analysis of sprayed coatings revealed a continuous and defect-free contact between substrate and coating. Ni-15Al₂O₃-5TiO₂ coating showed higher value of bond strength in comparison with Ni-20Al₂O₃ coating. Under all the testing conditions, Ni-15Al₂O₃-5TiO₂ coatings showed higher resistance to slurry erosion in comparison with Ni-20Al₂O₃ coatings. Rotational speed, average particle size of erodent and slurry concentration were found to have proportional effect on specific mass loss of coatings. The mixed behavior (brittle as well as ductile) of the material removal mechanism was observed for the coatings.

From the literature review, it was found that researchers have documented the various studies on Ni-Al₂O₃, Ni-TiO₂ and Al₂O₃-TiO₂ coatings. No one has ascertained the synergetic effect of Alumina and Titania on the slurry erosion performance of Nickel-based coating. In view of this, the authors have developed Ni-Al₂O₃ and Ni-Al₂O₃-TiO₂ coatings, and an attempt has been made to compare their mechanical, microstructural and slurry erosion characteristics.

Cavitation erosion has always been a common technical problem in a hydraulic discharging structure. This paper aims to investigate the cavitation erosion behavior of hydraulic concrete under high-speed flow.

A high-speed and high-pressure venturi cavitation erosion generator was used to simulate the strong cavitation. The characteristics of hydrodynamic loads of cavitation bubble collapse zone, the failure characteristics and the erosion development process of concrete were investigated. The main influencing factors of cavitation erosion were discussed.

The collapse of the cavitation bubble group produced a high frequency, continuous and unsteady pulse load on the wall of concrete, which was more likely to cause fatigue failure of concrete materials. The cavitation action position and the main frequency of impact load were greatly affected by the downstream pressure. A power exponential relationship between cavitation load, cavitation erosion and flow speed was observed. With the increase of concrete strength, the degree of damage of cavitation erosion was approximately linearly reduced.

After cavitation erosion, a skeleton structure was formed by the accumulation of granular particles, and the relatively independent bulk structure of the surface differed from the flake structure formed after abrasion.

This study aims to examine solid particle erosion behavior of novel hybrid composite materials where borax (B₂O₃) particles (∼150 μm) were added to glass fabric and epoxy resin at an amount of 15 and 30 per cent.

The tests that involved slightly rounded and irregular Al₂O₃ particles having two erodent sizes (200, 400 μm) were conducted at these operational conditions; namely, three impact velocities (23, 34, 53 m/s), two fabric directions (0/90/0, 45/−45/45) and three impingement angles (30°, 60°, 90°). In addition, the design of experiments, which utilizes Taguchi’s robust orthogonal arrays approach, was used and an optimum parameter combination was established, which had a minimum erosion rate. Moreover, scanning electron microscope and X-ray diffraction views show the visual effect of filler material.

All test specimens regardless of their dissimilar characteristics displayed maximum erosion rate at 30° impingement angle. Test specimens with 45/−45/45 fabric direction are more wear-resistant than their counterparts with 0/90/0 fabric direction. The erosion wear of glass fabric reinforced epoxy (GF/EP) composites whose matrix had 15 per cent addition of borax particles was higher than that of neat GF/EP composites. In addition, new composite material formed by including borax particles at a rate of 30 per cent of resin leads to a reduction in erosion rates.

While fabric-reinforced polymers take place in most of the studies conducted on erosive wear of composites, studies involving erosion on composites with filler materials can hardly be encountered.

In the present study, Al₂O₃ coatings were deposited on stainless steel AISI-304 material by using atmospheric plasma spraying technique to combat high temperature solid particle erosion. The present aims at the performance analysis of Al₂O₃ coatings at high temperature conditions.

The erosion studies were carried out at a temperature of 400°C by using a hot air-jet erosion tester for 30° and 90° impingement angles. The possible erosion mechanisms were analyzed from scanning electron microscope (SEM) micrographs. Surface characterization of the powder and coatings were conducted by using an X-ray diffractometer, SEM, equipped with an energy dispersive X-ray analyzer. The porosity, surface roughness and micro-hardness of the as-sprayed coating were measured. This paper discusses outcomes of the commonly used thermal spray technology, namely, the plasma spray method to provide protection against erosion.

The plasma spraying method was used to successfully deposit Al₂O₃ coating onto the AISI 304 substrate material. Detailed microstructural and mechanical investigations were carried out to understand the structure-property correlations. Major findings were summarized as under: the erosive wear test results indicate that the plasma sprayed coating could protect the substrate at both 30° and 90° impact angles. The coating shows better resistance at an impact angle of 30° compared with 90°, which is related to the pinning and shielding effect of the alumina particle. The major erosion wear mechanisms of Al₂O₃ coating were micro-cutting, micro-ploughing, splat removal and detachment of Al₂O₃ hard particles.

In the current study, the authors have followed the standard testing method of hot air jet erosion test as per American society for testing of materials G76-02 standard and reported the erosion behavior of the eroded samples. The coating was not removed at all even after the erosion test duration i.e. 10 min. The erosion test was continued till 3 h to understand the evolution of coatings and the same has been explained in the erosion mechanism. The outcome of the present study may be used to minimize the high temperature erosion of AISI-304 substrate.

The purpose of this paper is to investigate the combined erosion and corrosion behavior of WC-Ni vacuum brazed coating.

Al₂O₃ particles and 10 wt% NaCl solution are used to evaluate erosion and corrosion resistance of WC-Ni vacuum brazed coating. Combined test of erosion and corrosion is also conducted. The microstructure of each specimen is characterized by the scanning electron microscopy. The chemical composition was determined by energy-dispersive X-ray spectroscopy.

WC-Ni vacuum brazed coating layer is effective protective coating under combined erosion and corrosion environment. The weight loss of coating layer is more reduced as the cumulative test time.

WC-Ni vacuum brazed coatings are investigated to check characteristic of the combined erosion and corrosion environment. WC-Ni vacuum brazed coatings are kind of diffusion coating that attract attention because of the resistance of superb impact and corrosion in comparison with other coatings. Some previous researches reported the properties of vacuum brazed WC material. Erosion and corrosion behaviors of WC-Ni vacuum brazed coatings were studied in our previous research, respectively. Hence, in this research, the principal objective is to examine the combined erosion and corrosion behavior of WC-Ni vacuum brazed coating.

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.

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.

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.

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.

This paper seeks to summarise the results of available research on the use of high velocity oxy‐fuel (HVOF) thermal‐spray technique to provide protection against high temperature corrosion and erosion‐corrosion of materials.

This paper describes one of the recent thermal‐spray processes, namely HVOF thermal‐spray technology and presents a survey of the studies on the use of this technique to provide protection against corrosion and erosion‐corrosion of high temperature alloys, with a special emphasis on boiler steels.

High temperature corrosion and erosion‐corrosion are serious problems observed in steam‐powered electricity generation plants, gas turbines, internal combustion engines, fluidized bed combustors, industrial waste incinerators and recovery boilers in paper and pulp industries. These problems can be prevented by changing the material or altering the environment, or by separating the component surface from the environment. Corrosion prevention by the use of coatings for separating materials from the environment is gaining importance in surface engineering. Amongst various surface modifying techniques, thermal spraying has developed relatively rapidly due to the use of advanced coating formulations and improvements in coating application technology. One of the variants of thermal spraying, namely HVOF has gained popularity in recent times due to its flexibility for in‐situ applications and superior coating properties.

This review covers mainly information that has been reported previously in the open literature, international journals and some well‐known textbooks.

The paper presents a concise summary of information for scientists and academics, planning to start their research work in the area of surface engineering.

This paper fulfils an identified information/resources need and offers practical help to an individual starting out on a career in the area of surface engineering for erosion‐corrosion and wear.

The dissolution rates of iron and alloyed steels in molten lead‐free solders were investigated in order to clarify the effect of erosion of iron plating on soldering iron tips. The dissolution rates of iron‐based alloys in lead‐free solders were found to be about three times greater than in conventional Sn‐Pb eutectics, indicating that the iron plating of a soldering iron tip is subjected to heavier damage when used with lead‐free rather than eutectic Sn‐Pb. Several steel alloys showed dissolution rates similar to that of pure iron, suggesting that compositional changes in the iron plating may have little influence on the erosion depth. Decreases in the reaction temperature and time, and a small addition of iron into the solder was found to be effective in suppressing both dissolution of iron wire and erosion of iron plating.

This empirical study aims to investigate the erosion wear performance of two different 3D-printed materials (acrylonitrile butadiene styrene [ABS] and polylactic acid [PLA]) with various micro textures. The two different textures (prism and square) were created over the surfaces of both materials by using the 3D-printed technique.

The erosion experiments on both materials were performed by using Ducom Erosion Jet Tester. Erosion tests were performed at four different impacting velocities (15, 30, 45 and 60 m/s) with the four different particle sizes (17, 39, 63 97 µm) at the impact angles (30°–90°) for the time duration of 5, 10, 15 and 20 min. The two different textures prism and cone were used for performing the erosion experiments. Taguchi’s orthogonal L16 (mixed level) was used to reduce the number of experiments and to determine the impact of these parameters on erosion wear performance of both 3D-printed materials.

The PLA with cone texture was found to be best (against erosion) than the ABS cone and prism textures due to their high hardness (68 HV). Also, the average signal to noise (S/N) ratio for PLA and ABS was measured as 56.4 and 44.4 dB, respectively. As the value of the S/N ratio is inversely proportional to the erosion rate, the PLA has the least erosion rate as compared to the ABS. The sequence of erosion wear influencing parameters for both materials was in the following order: velocity > erodent size > texture > impact angle > time interval.

Both PLA and ABS with different micro textures for erosion testing were studied with Taguchi’s optimization method, and the erosion mechanisms are well analyzed by using scanning electron microscopy and Image J techniques.

Nowadays, application of biopolymers on geotechnical engineering works is booming to avoid the harsh effects on environment by using conventional methods for soil treatment. In this present study, xanthan gum (XG) is used as a biopolymer to improve dispersive properties of the soils because these soils are easily prone to erosion, which may lead to the damage of many hydraulic structures.

In the present study, attempts are made to reduce the dispersive potential and increase the Strength and erosion resistance by treating the soils with various percentages of XG (0.5%, 1%, 1.5% and 2%). To assess the dispersive potential and erosion resistance of soils, tests such as double hydrometer test, pinhole erosion test, crumb test and cylinder dispersion test were conducted. Further tests were expanded for its geotechnical characteristics such as Atterberg’s limits, standard proctor test, unconfined compressive strength test, one-dimensional consolidation for various curing days. Scanning electron microscopy analysis was also carried out to know the microscopic view towards its particle orientation and bindings. Chemical tests such as sodium absorption ratio, total dissolved solids (TDS) and percentage sodium (PS), electronic conductivity and pH tests were also conducted.

The results revealed that there is a reduction in the dispersive potential of XG treated soils for all the combinations. Addition of XG decreased the PS in the soil as a result dispersivity of soil decreased. Strength and erosion resistance of soil increased with the addition of XG and 1% XG was observed to be the optimum percentage for stabilizing these types of soils.

These results will be very much helpful for engineers when they come across with dispersive soils for better handling and management.

The originality of this study was an attempt towards sustainable development by treating dispersive soils with XG and effects on various geotechnical and dispersive characterizes.