Skip to main content
SpringerLink
Log in

A Phenomenological Model for Slurry Erosion Prediction of Thermal Spray Coatings

  • Original Paper
  • Published:
Tribology Letters Aims and scope Submit manuscript

Abstract

Erosion is a serious concern for machinery dealing with particle-laden fluids. For protection against erosion, coatings are usually recommended. Laboratory experiments are conducted to evaluate the erosion rates of these coatings. Alternatively, one could consider the use of modeling and simulation to predict the erosion rates. Although several models are available in literature for bulk materials, there is limited work reported in this direction for coatings. In present work, several models from literature were evaluated for their ability to predict the slurry erosion of coatings. A model based upon contact-fracture theory (CFT), proposed in present work, was also evaluated. Another variant of this model considered the effect of splat size. It was observed that none of the existing models evaluated in the present work could predict the erosion rates of the coatings. The proposed CFT model was able to predict the erosion rates with reasonable accuracy, whereas another variant of this model based upon splat size was observed to be inappropriate for predicting erosion rates of coatings. Possible reasons for the observed disparity are discussed.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Abbreviations

A(h):

Area function

C, D :

Constants

E :

Young’s modulus (Pa)

E * :

Equivalent Young’s modulus (Pa)

E r,m :

Erosion rate (mm3/s) or (g/g)

H :

Hardness (Pa)

I 1, I 2 :

Constants

K c :

Fracture toughness of target material (Pa√m)

K w :

Coefficient depending upon material parameters

P :

Impact force (N)

Q :

Volume loss (m3)

R p :

Radius of erodent particle (m)

U KE :

Kinetic energy (Nm)

V :

Impact velocity of erodent (m/s)

W ind :

Work of indentation (Nm)

a :

Radius of contact/plastic zone (m)

b :

Depth of plastic zone (m)

c lat :

Length of lateral crack (m)

d :

Diameter of erodent particle (m)

e :

Constant

f :

Coefficient of friction

h :

Indentation depth (m)

m :

Mass of erodent (Kg)

m′:

Constant

\(\dot{m}_{a}\) :

Mass flux rate (Kg/s)

n :

Exponent of cross-sectional area cut by particle

p o :

Maximum pressure (Pa)

r :

Radius of crater (m)

r y :

Radius of plastically deformed zone (m)

t :

Thickness of coating (m)

z :

Axial distance normal to contact zone (m)

α :

Angle of jet exit (deg)

ε c :

Critical strain

ε t :

Ductility

θ :

Impact angle (deg)

ν :

Poisson’s ratio

μ :

Constant

σ r,σ y :

Radial and yield stress (Pa)

Ψ :

Angle representing the variation in plastically deformed zone

n:

Normal direction

t:

Tangential direction

p:

Particle

T:

Target

References

  1. Mann, B.S.: High-energy particle impact wear resistance of hard coatings and their application in hydroturbines. Wear 237, 140–146 (2000)

    Article  Google Scholar 

  2. Duan, C., Karelin, V.I.A.: Abrasive Erosion & Corrosion of Hydraulic Machinery. Imperial College Press, Covent Garden (2002)

    Google Scholar 

  3. Pawlowski, L.: The Science and Engineering of Thermal Spray Coatings. Wiley, Hoboken (2008)

    Book  Google Scholar 

  4. Pauleau, Y.: Materials Surface Processing by Directed Energy Techniques. Elsevier Science, Amsterdam (2006)

    Google Scholar 

  5. Bingley, M., Oflynn, D.: Examination and comparison of various erosive wear models. Wear 258(1–4), 511–525 (2005)

    Article  Google Scholar 

  6. Hutchings, I.: Prediction of the resistance of metals to erosion by solid particles. Wear 35, 371–374 (1975)

    Article  Google Scholar 

  7. Hutchings, I.: A model for the erosion of metals by spherical particles at normal incidence. Wear 70, 269–281 (1981)

    Article  Google Scholar 

  8. Sundararajan, G.: A comprehensive model for the solid particle ductile materials. Wear 149, 111–127 (1991)

    Article  Google Scholar 

  9. Finnie, I.: Erosion of surfaces by solid particles. Wear 3(2), 87–103 (1960)

    Article  Google Scholar 

  10. Bitter, J.G.A.: A study of erosion phenomena-Part I. Wear 6, 5–21 (1963)

    Article  Google Scholar 

  11. Huang, C., Chiovelli, S., Minev, P., Luo, J., Nandakumar, K.: A comprehensive phenomenological model for erosion of materials in jet flow. Powder Technol. 187(3), 273–279 (2008)

    Article  Google Scholar 

  12. Meng, H.C., Ludema, K.C.: Wear models and predictive equations: their form and content. Wear 181–183((Part 2)), 443–457 (1995)

    Article  Google Scholar 

  13. Burnett, A.J., Pittman, A.N., Bradley, M.S.A.: Observations on and the modelling of erosive wear of a long-radius pneumatic conveyor bend. J. Eng. Tribol. 212(5), 369–379 (1998)

    Google Scholar 

  14. Deng, T., Chaudhry, A.R., Patel, M., Hutchings, I., Bradley, M.S.A.: Effect of particle concentration on erosion rate of mild steel bends in a pneumatic conveyor. Wear 258(1–4), 480–487 (2005)

    Article  Google Scholar 

  15. Rajahram, S.S., Harvey, T.J., Wood, R.J.K.: Evaluation of a semi-empirical model in predicting erosion-corrosion. Wear 267(11), 1883–1893 (2009)

    Article  Google Scholar 

  16. Grewal, H.S., Singh, H., Agrawal, A.: Numerical simulation of erosion using computational fluid dynamics. Simul. Mater. Process., 141st TMS Annual Meeting, pp 89–96 (2012)

  17. Atkinson, M., Stepanov, E.V., Goulet, D.P., Sherikar, S.V., Hunter, J.: High pressure testing sand erosion in 3D flow channels and correlation with CFD. Wear 263(1–6), 270–277 (2007)

    Article  Google Scholar 

  18. Gnanavelu, A., Kapur, N., Neville, A., Flores, J.F., Ghorbani, N.: A numerical investigation of a geometry independent integrated method to predict erosion rates in slurry erosion. Wear 271(5–6), 712–719 (2011)

    Article  Google Scholar 

  19. Lyczkowski, R.W., Bouillard, J.X.: State-of-the-art review of erosion modeling in fluid/solids systems. Prog. Energy Combust. Sci. 28(6), 543–602 (2002)

    Article  Google Scholar 

  20. Evans, A.G., Gulden, M.E., Rosenblatt, M.: Impact damage in brittle materials in the elastic-plastic response regime. Proc. R. Soc. Lond. Ser. A 361(1706), 343–365 (1978)

    Article  Google Scholar 

  21. Abdel-Rahman, A.A., El-Domiaty, A.A.: Maximum depth of cut for ceramics using abrasive waterjet technique. Wear 218(2), 216–222 (1998)

    Article  Google Scholar 

  22. Aquaro, D.: Erosion due to the impact of solid particles of materials resistant at high temperature. Acta Meccanica 41(5), 539–551 (2006)

    Article  Google Scholar 

  23. Aquaro, D., Fontani, E.: Erosion of ductile and brittle materials. Acta Meccanica 36, 651–661 (2002)

    Article  Google Scholar 

  24. Wiederhorn, S.M., Lawn, B.R.: Strength degradation of glass resulting from impact with spheres. J. Am. Ceram. Soc. 60(9–10), 451–458 (1977)

    Article  Google Scholar 

  25. Hassani, S., Bielawski, M., Beres, W., Martinu, L., Balazinski, M., Klembergsapieha, J.: Predictive tools for the design of erosion resistant coatings. Surf. Coat. Technol. 203(3–4), 204–210 (2008)

    Article  Google Scholar 

  26. Argatov, I.I., Dmitriev, N.N., Petrov, Y.V., Smirnov, V.I.: Threshold erosion fracture in the case of oblique incidence. J. Frict. Wear 30(3), 176–181 (2009)

    Article  Google Scholar 

  27. Hutchings, I.M.: Tribology: Friction and Wear of Engineering Materials. Edward Arnold, London (1992)

    Google Scholar 

  28. Slikkerveer, P.J., Bouten, P.C.P., in’t Veld, F.H., Scholten, H.: Erosion and damage by sharp particles. Wear 217(2), 237–250 (1998)

    Article  Google Scholar 

  29. Marshall, D.B., Lawn, B.R., Evans, A.G.: Elastic/plastic indentation damage in ceramics: the lateral crack system. J. Am. Ceram. Soc. 65(11), 561–566 (1982)

    Article  Google Scholar 

  30. Hill, R.: The Mathematical Theory of Plasticity. Clarendon Press, Oxford (1967)

    Google Scholar 

  31. Verspui, M.A.: Simulation model for the erosion of brittle materials. Wear 233–235, 436–443 (1999)

    Article  Google Scholar 

  32. Routbort, J.L., Scattergood, R.O., Turner, A.P.L.: The erosion of reaction-bonded SiC. Wear 59(2), 363–375 (1980)

    Article  Google Scholar 

  33. Fang, Q., Sidky, P.S., Hocking, G.M.: Erosion resistance of continuously reinforced SiC-Ti-based metal matrix composites by a SiC/water slurry jet. Wear 233–235, 174–181 (1999)

    Article  Google Scholar 

  34. Sheldon, G.L., Finnie, I.: On the ductile behavior of nominally brittle materials during erosive cutting. J. Eng. Ind. 88(4), 387–392 (1966)

    Article  Google Scholar 

  35. Johnson, K.L.: Contact Mechanics. Cambridge University Press, Cambridge (1987)

    Google Scholar 

  36. Evans, A.G., Fleck, N.A., Faulhaber, S., Vermaak, N., Maloney, M., Darolia, R.: Scaling laws governing the erosion and impact resistance of thermal barrier coatings. Wear 260(7–8), 886–894 (2006)

    Article  Google Scholar 

  37. Anderson, T.L.: Fracture Mechanics: Fundamentals and Applications. Taylor & Francis, UK (2005)

    Google Scholar 

  38. Grewal, H.S., Singh, H., Agrawal, A.: Microstructural and mechanical characterization of thermal sprayed nickel–alumina composite coatings. Surf. Coat. Technol. 216, 78–92 (2013)

    Article  Google Scholar 

  39. Grewal, H.S., Agrawal, A., Singh, H.: Design and development of high-velocity slurry erosion test rig using CFD. J. Mater. Eng. Perform. 22(1), 152–161 (2013)

    Article  Google Scholar 

  40. ASTM Standard G73: Standard Test Method for Liquid Impingement Erosion Using Rotating Apparatus. ASTM International, West Conshohocken, PA, 2010, doi: 10.1520/G0073-10, www.astm.org

  41. Grewal, H.S., Agrawal, A., Singh, H.: Slurry erosion performance of Ni–Al2O3 based thermally sprayed coatings: effect of angle of impingement. J. Therm. Spray Technol. 23(3), 389–401 (2014)

    Article  Google Scholar 

  42. Grewal, H.S., Singh, H., Agrawal, A.: Slurry erosion performance of Ni–Al2O3 based composite coatings. Tribol. Int. 66(3), 296–306 (2013)

    Article  Google Scholar 

  43. Tabor, D.: The Hardness of Metals. Oxford University Press, Oxford (2000)

    Google Scholar 

  44. Levy, A.V.: Solid particle erosion and erosion-corrosion of materials. ASM Int (1995)

Download references

Acknowledgments

Authors thankfully acknowledge the financial assistance provided by Council of Scientific and Industrial Research (CSIR), India, under project title ‘Development of Slurry Erosion Resistant Coatings for Hydroturbines’ [File no.: 22(0604)/12/EMR-II].

Author information

Authors and Affiliations

  1. School of Mechanical, Materials and Energy Engineering, Indian Institute of Technology Ropar, Nangal Road, Rupnagar, 140001, Punjab, India

    H. S. Grewal, H. Singh & Anupam Agrawal

Authors
  1. H. S. Grewal
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. H. Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Anupam Agrawal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to H. Singh.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Grewal, H.S., Singh, H. & Agrawal, A. A Phenomenological Model for Slurry Erosion Prediction of Thermal Spray Coatings. Tribol Lett 56, 119–132 (2014). https://doi.org/10.1007/s11249-014-0391-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11249-014-0391-3

Keywords

Search

Navigation