Search Results (161)

Cavitation-induced degradation of metallic materials presents a significant challenge for engineers and users of equipment operating with high-velocity fluids. For any metallic material, the mechanical strength and ductility characteristics are controlled by the mobility of dislocations and their interaction with other defects in the crystal lattice (such as dissolved foreign atoms, grain boundaries, phase separation surfaces, etc.). The increase in mechanical properties, and consequently the resistance to cavitation erosion, is possible through the application of heat treatments and cold plastic deformation processes. These factors induce a series of hardening mechanisms that create structural barriers limiting the mobility of dislocations. Cavitation tests involve exposing a specimen to repeated short-duration erosion cycles, followed by mass loss measurements and surface morphology examinations using optical microscopy and scanning electron microscopy (SEM). The results obtained allow for a detailed study of the actual wear processes affecting the tested material and provide a solid foundation for understanding the degradation mechanism. The tested material is the Ni-based alloy INCONEL 625, subjected to stress-relief annealing heat treatment. Experiments were conducted using an ultrasonic vibratory device operating at a frequency of 20 kHz and an amplitude of 50 µm. Microstructural analyses showed that slip bands formed due to shock wave impacts serve as preferential sites for fatigue failure of the material. Material removal occurs along these slip bands, and microjets result in pits with sizes of several micrometers. Full article

In this study, solid particle erosion tests were conducted to evaluate the resistance of AISI 4340 (EN24) and 8620 alloy steels against silicon carbide (SiC). These steels were selected due to their high hardness, yield strength (σ_y), ultimate tensile strength (σ_uts) and elongation (%), which are significant parameters, influencing wear resistance. An erosion rig based on the ASTM G76-95 standard was used to perform the testing. Tests were carried out using different impact angles, 30°, 45°, 60° and 90°, with a particle velocity of 24 ± 2 m/s. The abrasive flow rate was 0.7 ± 0.5 g/min and the temperature was between 35 °C and 40 °C. Characterization techniques such as SEM were employed to identify the chemical composition of AISI 4340 and AISI 8620 steels and optical microscopy to determine the morphology of SiC abrasive particles. In addition, the SiC particle size was between 350 and 450 µm; it was determined by the particle size distribution technique. SEM micrographs were obtained to classify the wear mechanisms, characterized by micro-cutting, micro-ploughing, grooves, pitting actions and embedded particles on the surface at 30° and 90°. The results showed that AISI 8620 steel exhibited higher erosion resistance than AISI 4340 steel. Finally, AFM was used to evaluate the roughness variations before and after erosion tests, specifically in the central zone of the wear scars at 30° and 90° for both materials. Full article

Cu-5wt%TiC coatings were fabricated by high-speed laser cladding on the 7075 aluminum alloy substrate using various scanning speeds to improve its current-carrying wear resistance. The effects of scanning speed on the microstructure, phase, hardness, and current-carrying tribological properties of the coating were investigated using a scanning electron microscope, an X-ray diffractometer, a hardness tester, and a wear tester, respectively. The results show that the increase in scanning speed accelerates the coating’s solidification rate. Among the samples, the coating comprised of equiaxed crystals prepared at 149.7 mm/s presents the best quality, but solidification speeds that are too rapid lead to elemental segregation. The hardness of the coating also decreases with the increase in scanning speed. The coating prepared at 149.7 mm/s exhibits the best wear resistance and electrical conductivity. The wear rate of the coating prepared at 149.7 mm/s at 25 A was 4 × 10⁻³ mg·m⁻¹, respectively. During the current-carrying friction process, the presence of thermal effects and arc erosion cause the worn track to be prone to oxidation, adhesion, and plastic deformation, so the current-carrying wear mechanisms of coatings at 25 A include adhesive wear, oxidation wear, and electrical damage. Full article

This study explored the enzymatic formation of gel-like polymeric matrices through carbonate precipitation for dust suppression in Yellow River silt. The hydrogel-modified EICP method effectively enhanced the compressive strength and resistance to wind–rain erosion by forming a reinforced bio-cemented crust. The optimal cementation solution, consisting of urea and CaCl₂ at equimolar concentrations of 1.25 mol/L, was applied to improve CaCO₃ precipitation uniformity. A spraying volume of 4 L/m² (first urea-CaCl₂ solution, followed by urease solution) yielded a 14.9 mm thick hybrid gel-CaCO₃ crust with compressive strength exceeding 752 kPa. SEM analysis confirmed the synergistic interaction between CaCO₃ crystals and the gel matrix, where the hydrogel network acted as a nucleation template, enhancing crystal bridging and pore-filling efficiency. XRD analysis further supported the formation of a stable gel-CaCO₃ composite structure, which exhibited superior resistance to wind–rain erosion and mechanical wear. These findings suggest that gel-enhanced EICP represents a novel bio-gel composite technology for sustainable dust mitigation in silt soils. Full article

The resistance to erosion of stainless steel-based plasma transferred arc (PTA)-cladded hardfacings reinforced with ex-situ-synthesized TiC is compared to those reinforced using in-situ-synthesized TiC (formed from TiO₂ and graphite). The PTA cladding was performed under an optimized torch linear velocity of 0.7 m/s and cladding current of 115 A. The microstructure of the cladded overlay was analyzed using scanning electron microscopy (SEM), and the phase composition was determined using X-ray diffraction (XRD). Vickers macrohardness measurements were made at representative areas at the surface of the overlays. An erosive wear test was conducted with impact angles of 30° and 90° and impact velocities of 20, 50, and 80 m/s. The formation of TiC from TiO₂ and graphite started during ball milling and ended during the cladding stage. The final TiC content in the hardfacings was below nominal, which is likely due to carbide segregation occurring during the cladding process. The highest hardness was 2.4 times that of stainless steel, which was observed in the deposit containing 60 vol.% ex-situ-synthesized TiC. Both ex-situ and in-situ TiC reinforcement improved resistance to erosion, providing up to 1.5 times better resistance under the 30° impact angle and up to 6.3 times under the 90° impact angle than that of stainless steel. However, ex-situ TiC showed a slightly larger improvement. At the 30° impact angle, the primary wear mechanism is micro-ploughing, but at the 90° impact angle it is surface fatigue. Both mechanisms appeared at both angles under 80 m/s impact velocity. Full article

This is a research study on the high-temperature solid particle erosion behavior of basalt/carbon hybrid composites with varying ply arrangements (B₈, C₈, B₄C₄, C₄B₄, B₂C₄B₂, and C₂B₄C₂). Solid particle erosion experiments were carried out by employing garnet particles at temperatures of 25 °C, 50 °C, 80 °C, and 120 °C at impingement angles of 30° and 90°. The erosion weight loss rate differed substantially with the temperature, angle of impact, and ply arrangement. The highest erosion rates were obtained by single-component composites at 544.9 mg/g (B8, 120 °C, 30°) and 541.3 mg/g (C₈, 120 °C, 90°). In contrast, the hybrid composites were more resistant, with the lowest rate being 200.0 mg/g at an ambient temperature (25 °C, 30°) for C₄B₄. The erosion weight loss at 50 °C increased typically due to thermal softening, whereas at elevated temperatures (80 °C, 120 °C), there was some stabilization seen, reflecting the positive synergies between basalt and carbon fibers. The factorial analysis of ANOVA revealed that material type (43.17%) was the most significant factor, followed by the temperature (19.97%) and impingement angle (0.52%). SEM and profilometry analysis confirmed that hybrid arrangements lower the erosion crater depth by a great extent, affirming the improved wear resistance of balanced basalt-carbon configurations. This work demonstrates the potential applications of optimally designed hybrid composites for durability under erosive high-temperature environments. Full article

Due to the low hardness of carbon steels, their low resistance to wear, and erosion by cavitation and corrosion, it is necessary to protect the surfaces of parts with layers capable of ensuring the properties listed above. In this paper, we started from the premise that adding tungsten carbide (WC) powders during the electric arc spraying process of stainless steel would lead to obtaining a composite material coating resistant to wear and erosion at high temperatures, with relatively lower manufacturing costs. Thus, our research compared the following two types of coatings: a highly alloyed layer with WC, Cr, and TiC (obtained from 97MXC core wires) and a 60T/WC coating (obtained from a 60T solid-section wire to which WC was added), in terms of microstructure, mechanical properties, dry friction wear, and behaviour at erosion by cavitation (EC). The results of our research demonstrated that although the 60T/WC coating had lower erosion by cavitation behaviour than the 97MXC one, it can still be considered as a relatively good and inexpensive solution for protecting C15 steel parts. Full article

Valve leakage mainly comes from worn sealing surfaces caused by abrasive particles. This study uses plasma beam spraying to create Fe55 alloy coatings with CeO₂ and TiN added to improve microstructure and wear resistance. Five coatings were prepared: Fe55 with 0.02% CeO₂ (FC2), 0.04% CeO₂ (FC4), 1% TiN (FT1), 2% TiN (FT2), and 2% TiN/0.02% CeO₂ (FC2T2). These coatings were tested for wear and erosion using wet sand and slurry experiments. Results showed that FC2T2 had the most uniform microstructure with fully equiaxed grains (20.32 μm size) and no columnar grains. This was due to CeO₂ and TiN co-working effect: CeO₂ was adsorbed onto TiN surfaces, reducing TiN decomposition and acting as nucleation sites. The FC2T2 coating also showed the highest hardness uniformity (no large changes with depth) and the lowest surface roughness after wear (41% lower than pure Fe55). In wear tests, FC2T2’s Cr₇C₃ hard phases blocked abrasive cutting, while the γ-Fe matrix prevented Cr₇C₃ from breaking off. Erosion tests confirmed FC2T2’s superior performance, as its uniform structure limited deep grooves. Adding both CeO₂ and TiN improved wear resistance by providing a balanced microstructure, reducing leakage risks in valve sealing surfaces. Full article

The Al/W composite layer was fabricated on the surface of the aluminum alloy using laser alloying technology to enhance the current-carrying wear resistance. Additionally, the current-carrying wear behaviors of the Al/W composite layer and the aluminum alloy substrate were investigated under different currents. The results indicate that the presence of hard phases such as W and Al₄W in the composite layer significantly enhanced the wear resistance of the material. Specifically, the average friction coefficient of the Al/W composite layer under different currents was reduced by approximately 9.3–35.8% compared to the aluminum alloy substrate, and the wear rate under current-carrying conditions decreased by about 1.9–6.0 times. For the aluminum alloy substrate, adhesive wear is the dominant mechanism under currents ranging from 0 to 60 A. However, as the current increased to 80 A, the severity of arc erosion intensified, and the wear mechanism transitioned to a combination of arc erosion and adhesive wear. In contrast, for the Al/W composite layer, abrasive wear was the dominant wear mechanism in the absence of electrical current. Upon the introduction of the current, the wear mechanism changed to a coupling effect of arc erosion and adhesive wear. Full article

Erosive wear of materials caused by solid particles leads to severe damage on the surface of structure materials and results in mechanical failures. Erosion has been extensively studied for many years in terms of mechanisms, material properties, and impact dynamics. Since the early 21st century, little progress has been made on the evaluation of surface erosive failure due to multiple impacts of particulate solids. The major difficulty is the enormous number of variables involved in the erosion process. However, the existing theories are only able to take a few of them and end up with many assumptions on the others. In summary, the influential factors on erosion can be classified as impact dynamics (such as velocity and angles), mechanisms of material failures (deformation, cutting, and cracking), and material properties of solids and the surface (hardness, toughness, ductility, and brittleness). In this paper, erosion mechanisms and progress from the existing theories have been reviewed critically, which gives a better understanding of the phenomenon. Based on the review of the influential factors in terms of contributions to the process, proper evaluation methods of the erosion process have been discussed, which leads to further thinking of better assessments. Full article

Marine environment-induced apparatus failures have led to substantial losses in marine engineering. Graphite/copper composites, known for their excellent electrical conductivity and wear resistance, are extensively utilized in various electric contact devices. However, research on the current-carrying friction and wear behavior of graphite/copper composites in marine environments is still limited. This study investigates the effects of mating materials, graphite content (30 wt.% and 45 wt.%), and electric voltage on the friction and wear mechanisms of graphite/copper composites in seawater. The results show that under seawater coupled with electricity, no mass loss was observed in the 30 wt.% graphite composites after friction tests against different counterparts. Electric voltage (3 V) affects the composite’s damage mechanism, inducing delamination wear, arc erosion and accelerating corrosion. Specifically, the electricity factor promotes oxidation recreations while inhibiting chlorine formation. Notably, when the composite is paired with gold-coated copper, it undergoes electrochemical reactions, leading to the formation of needle-like copper oxide. These oxides alter the surface morphology, elevate the mass of worn composites, and raise the friction coefficient of the tribopair to approximately 0.3, an increase from 0.2. Full article

Lamellar graphite pearlitic grey cast irons are frequently used in the manufacturing of components that operate under cavitation erosion conditions. Their poor performance regarding cavitation erosion limits their use in intense cavitation environments. The physical modification of the surface layer offers a flexible and cost-effective way to combat cavitation attacks without altering the core properties. This paper comparatively analyzes the effects of four technological processing methods on the cavitation erosion resistance of grey cast irons. Cavitation erosion tests were conducted on a vibrating device with piezoceramic crystals in accordance with the ASTM G32-2016 standard. Surface hardness tests were carried out using a Vickers hardness tester, while roughness measurements were performed using a Mitutoyo device. The microstructures generated by the applied technologies and the surface wear mechanisms were analyzed using optical microscopy and scanning electron microscopy (SEM). The results indicated that the TIG local surface remelting process provides the most significant improvement in cavitation erosion resistance. Full article

The goal of this study is to investigate the surface morphology changes induced by the cavitation erosion of a coating based on cordierite with an epoxy matrix for an aluminum substrate. The literature review shows a certain lack of knowledge regarding the coating’s resistance to wearing induced by water flow, which is a highly important property of the material immersed in or in contact with water streams. The main idea behind the investigation is that such a protective coating will also improve the cavitation erosion resistance of metal substrates. The protective coatings were based on cordierite filler (88 wt.%) and epoxy resin (7 wt.%). The filler, made of a mixture of kaolin, alumina, and talc, is obtained by a sintering procedure that took place at 1350 °C. X-ray diffraction analysis and scanning electron microscopy were employed in the characterization of the produced filler. The adherence of the obtained epoxy-based protective coating and resistance to water flow were tested by the ultrasonic vibration method (i.e., cavitation erosion testing). Scanning electron microscopy was used for analysis of the coating’s morphology upon cavitation erosion. Based on the value of the cavitation erosion rate and the analyzed final surface damage, it was assessed that the investigated protective coating is resistant to cavitation erosion. Full article

The corrosive nature of ionic liquids (ILs) limits their potential as high-performance conductive lubricants in practical engineering applications. This study systematically investigates the effects of benzotriazole (BTA) as a corrosion inhibitor on the lubricating performance of ILs at different concentrations and applied currents, along with the underlying mechanisms. In the 0.5–5 A current range, BTA effectively reduces friction, wear, and arc erosion damage to the friction surface. As the applied current increases, the BTA-Fe reaction film suppresses oxide formation, thereby reducing electrical contact resistance (ECR). Moreover, the effectiveness of BTA is concentration-dependent: at 0.5 A and a BTA concentration of 0.5 wt%, the coefficient of friction (COF) decreases by 16.5%, and wear volume is reduced by 53.4%. Friction testing and surface analysis show that the BTA-IL combination exhibits synergistic lubrication and anti-corrosion effects under current-carrying conditions, with varying wear and lubrication mechanisms depending on the applied current. Full article

We used high-power impulse magnetron sputtering (HiPIMS) to deposit tungsten carbide films for superior wear protection in abrasive environments. In order to sample different W-to-C ratios more efficiently, a combinatorial approach was chosen. A single sputter target with two equal segments was used, consisting of an upper tungsten and lower graphite segment. This allowed us to vertically sample various elemental compositions in just one deposition run without creating graphitic nano-layers by rotating the substrate holder. The substrate bias voltage, being one of the most effective process parameters in physical vapor deposition (PVD), was applied in both constant and pulsed modes (the latter synchronized to the target pulse). A direct comparison of the different modes has not been performed so far for HiPIMS W-C (separated W and C targets). The resulting coating properties were mainly analyzed by nano-hardness testing and X-ray diffraction. In general, the W₂C phase prevailed in tungsten-rich coatings with pulsed bias, leading to slightly higher tungsten contents. Hardness reached maximum values of up to 35 GPa in the center region between the two segments, where a mix of W₂C and WC_1-x phases occurs. With pulsed bias, voltage hardnesses are slightly higher, especially for tungsten-rich films. In those cases, compressive stress was also found to be higher when compared to constant bias. Erosive wear testing by blasting with alumina grit showed that the material removal rate followed basically the coating’s hardness but surprisingly reached minimum wear loss for W₂C single-phase films just before maximum hardness. In contrast to previous findings, low friction that requires higher carbon contents of at least 50 at. % is not favorable for this type of wear. Full article