Erosive wears

N.A.G.Wilson
UWU/SCT/07/0047
Science & Technology Department
Materials Science & Technology Specialization
Uva Wellassa University of Sri Lanka
Content

 What is wear
 Types of wear
Adhesive wear
Abrasive wear
Surface fatigue
Erosive wear

Applications of erosive ware

References
 What is wear?
In materials science, wear is the
erosion of material from a solid
surface by the action of another
surface.

It is related to surface interactions and more specifically the removal of material from
a surface as a result of mechanical action.
Types of wear
Adhesive wear
Abrasive wear
Surface fatigue
Fretting wear
Erosive wear
Adhesive wear
Adhesive Wear
Adhesive wear occurs when two
smooth bodies are slid over each
other,
or
pressed in to another and fragment
are pulled off one surface and
adhere to the another and
fragment are pulled off one surface
and adhere to the other ,due to
the strong adhesive force between
atoms.
Adhesive Wear
Adhesive Wear
Abrasive wear
 Abrasive wear
Abrasive wear is a primary wear mechanism.

Particles enter the clearance space between two

moving surfaces, and act like cutting tools to
remove material from the surfaces.

The particle sizes causing the most damage are

those equal to and slightly larger than the
clearance space.

To protect opposing surfaces from abrasive

wear, particles of approximately the operating
clearance size range must be removed.
Abrasive wear
Abrasive wear
Surface Fatigue
 Surface Fatigue
When two surfaces slide across each
other, the maximum shear stress
lies some distance below the
surface, causing micro cracks,
which lead to failure of the
component. These cracks initiate
from the point where the shear
stress is maximum, and propagate
to the surface.
Schematic of fatigue wear, due to the formation of surface
and
subsurface cracks
Erosion
 Erosion

Erosion is caused by a gas or a liquid which

ordinarily carries entrained particles, impinging on a
surface with velocity.

 When the angle of impingement is smaller than 30

degrees, the wear-producing mechanism is closely
analogous to abrasion.

 When the angle of impingement is larger than 45

degrees to the surface, material is displaced by
plastic flow or is dislodged by brittle failure.

 We can conclude that erosion is dependent of the

size of the particles and the angle of impingement.
This type of wear is especially noticed in
components with high velocity flows such as
servo and proportional valves. Particles
repeatedly striking the surface may also cause
denting and eventual fatigue of the surface .
The SEM micrographs of Al
a). before
b). after 0.5 h erosion at 90o impact angle.
 Types of Erosive Wear
Various erosion modes are described according
to the erosive medium

 Liquid impingement erosion and cavitations

erosion

Solid particle erosion

Slurry erosion

Erosion/Corrosion
Liquid impingement erosion and
Liquid impingement erosion and
cavitations
cavitationserosion
erosion
liquid impingement erosion occurs when
small drops of liquid are striking on the
surface of a solid at high speed (1000 m/s)
and very high pressures are experienced,
exceeding the yield strength of most
materials
 Solid particle erosion

Solid particle erosion is the loss

of material that results from
repeated impact of small, solid
particles in a gaseous or liquid
medium
 Slurry erosion

Slurry erosion is defined as the

type of wear, or loss of mass, that
is experienced by material
exposed to a high-velocity
stream of slurry
Variables affecting the erosion can be broadly
classified into three types.
(1) impingement variables describing the particle flow:
† particle velocity
† angle of impact
† particle concentration

(2) particle variables:

† particle shape
† particle density
† particle size

(3) material variables (workpiece and particles):

† Young’s modulus
† Poisson’s ratio
† plastic behavior
† failure behavior
According to wear mechanism

Ductile

Brittle
Whether “brittle” or “ductile”
behavior is obtained for a particular
material may depend on

• Particle size

• Particle shape

• Impact speed

• Temperature
Small size: impact on defect
free area: plastic deformation

Large size: impact on defect

area: plastic deformation is not
possible brittle fracture occurs
Erosion of ductile materials
Erosion of ductile materials
Erosion of brittle materials
•Applications adversely affected by
erosion
Polymer processing machines and others
Coal plants (transport of pulverized coal)
Gas turbines
Power plants
Pipelines
Ship propellers
Aircraft
• Windshield
• Wings
• Propellers
• Rotors
Erosion of ductile materials
Erosive wear
SEM micro graph of surface eroded at 30°.
SEM micro graph of surface eroded at 45°
SEM micro graph of surface eroded at 60°.
SEM micrographs

(a) eroded at 90° (b) Magnified view of surface eroded at 90°

Referenses
Steve Roberts - Surface Engineering - Wear 23 Wear
Punyapriya Mishra and S. K. Acharya,Solid particle erosion
of Bagasse fiber reinforced epoxy
composite, Department of Mechanical Engineering, NIT,
Rourkela-769008, Orissa India.Accepted December 14, 2009
 Aino Helle, Peter Andersson, Tiina Ahlroos, Virpi
Kupiainen, Erosive wear of coatings and methods tomonitor
coating wear – A literature study, RESEARCH REPORT NO
BTUO43-041265 29.9.2004 VTT TECHNICAL RESEARCH CENTRE OF
FINLANDVTT INDUSTRIAL SYSTEMS
THANK YOU
 “ Adhesive” Wear by plasticity

Material is lost by fracture of asperities after contact

Asperity contact and junction formation

Fracture of one side of junction and material transfer

Secondary asperity contact leads to loss of transferred material

The rate of erosive wear is dependent upon a
number of factors. The material characteristics
of the particles, such as their shape, hardness,
impact velocity and impingement angle are
primary factors along with the properties of
the surface being eroded. The impingement
angle is one of the most important factors and
is widely recognized in literature. For ductile
materials the maximum wear rate is found
when the impingement angle is approximately
30o, whilst for non ductile materials the
maximum wear rate occurs when the
impingement angle is normal to the surface.