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An investigation has been carried out into the manufacture and field trial of alloy white iron beater plates used to process coal in a KSG coal pulveriser mill. The components were made by the cast bonding process, which involves casting a wear layer onto a steel substrate to form a bimetallic composite product. Four alloy white irons, containing primary and/or eutectic carbide volume fractions ranging...
A study has been made of the critical variables of particle type and size, flux and velocity on the erosion of a 1Cr Mo boiler tube steel up to temperatures of 600°C in a purpose-built air-blast laboratory rig. Whilst particle type has a slight effect on wastage, particle size, flux and velocity affect the magnitude of the erosion rate significantly.
This paper describes a study of the erosion of a polymer-particle coating system by a water jet apparatus. Modified versions of two established wear models were applied to this system; these were based on a simple hardness controlled abrasion model and a bulk toughness controlled abrasion model. The mechanical properties of the coatings were modified and their bulk properties were characterized using...
A number of parameters for characterizing the angularity of particles have been proposed in the literature. These parameters serve as good indicators of irregularity as opposed to roundness, but fail to provide a good measure of angularity. The relevant parameter in erosion is angularity and not irregularity. In this work, a new parameter for characterizing the angularity of particles is proposed...
Sialon-based ceramic composite materials containing 0-20 wt.% Si 3 N 4 whiskers were hot pressed and their mechanical properties and microstructural characterization were investigated. The specimens were subjected to ball-on-reciprocating plate type wear tests at temperatures between room temperature and 1073 K. A gas blast type erosion tester was employed to examine erosion behavior...
Plasma-sprayed coatings are built up from individual overlapping solidified droplets, and the nature of boundaries between these splats influences their mechanical and wear characteristics. This work aims to elucidate the correlation between these characteristics and microstructural features of model coatings produced under well-controlled processing conditions. A series of coatings with different...
High chromium white cast irons are used extensively in environments where small particle impact causes considerable damage. In this study, a white cast iron containing 26 wt% Cr, and with a carbide volume fraction of 0.28, is impacted with projectiles at normal incidence using a gas gun. Both crater diameter and the size of the damage zone are measured as a function of projectile velocity, and an...
To make paper from wood raw materials, wood chips must be processed to turn them into individual fibers or fiber bundles. In mechanical pulping this is accomplished by introducing energy into the wood chip or fiber bundles as the wood chips are passed between a set of counter-rotating plates; these are up to 1.5 m in diameter and operate with a plate clearance on the order of 0.1 mm and plate peripheral...
The dependence on the impact angle of erosion damage caused by solid particle impact was characterized on several kinds of material, as expressed by a trigonometric function of both impact angle and material hardness. Erosion tests were conducted on five metallic materials, a ceramic and a plastic material using silica sand particles (mean particle size 325 μm) at impact angles from 3° to 90°, up...
Two commercially available ceramics, a silicon carbide monolith and a silicon carbide-16 vol.% titanium diboride particle toughened ceramic matrix composite have been subjected to erosion by gas-borne silicon carbide particles over a range of experimental conditions, including erodent particle size and temperature. Material responses to single particle impacts and erosion have been correlated with...
The erosion behavior of Ni-base self-fluxing alloy, thermally sprayed coating on a metal substrate is affected by several factors, including the microstructure of the coatings, the porosity, the angle of impingement of solid particles and the hardness of the coatings. In this study, the erosion properties of thermally sprayed coatings with different tungsten carbide contents were investigated. Reinforced...
An experimental study was conducted to determine the influence of material properties on the surface integrity and texture that results from abrasive waterjet (AWJ) machining of metals. A microstructure analysis, microhardness measurements, and profilometry were used in determining the depth of plastic deformation and surface texture that result from material removal. Models now available for dry...
A series of experiments was carried out to quantify the wear properties for a wide range of ferritic FeCrC cast alloys at a temperature of 450°C. The main alloying elements of the alloys were varied as follows: 0.10%–2.48% C, 15%–43.8% Cr, 0.2%–0.51% Si. A semi-empirical model, based on Bitter's model of erosive wear, has been developed to describe the wear of these alloys as a function of chemical...
A semi-empirical model describing wear resistance of FeCrC white cast irons as a function of chemical composition and wear conditions has been used to analyse the effects of alloy composition. A wear criterion has been developed and then used to define an optimum alloy composition for a given set of wear conditions. The analysis is showed clearly that differing wear conditions require considerably...
The influence of cutting parameters and material properties on the residual stress fields resulting from abrasive waterjet (AWJ) machining of metals was analyzed. The measurement and evaluation were conducted using X-ray diffraction with the sin 2 ψ and X-ray integral method (RIM) of analyses. For all materials and cutting conditions, a significant bi-axial compressive residual stress was...
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