Editorial

2 pages, 175 KiB

Open AccessEditorial

Cavitation Erosion, Abrasive and Sliding Wear Behavior of Metal-Based Structures

by Mirosław Szala

Metals 2022, 12(3), 373; https://doi.org/10.3390/met12030373 - 22 Feb 2022

Cited by 2 | Viewed by 1224

The literature includes systematic studies of the wear behavior and phenomena responsible for a material’s degradation resistance [...] Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

Research

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24 pages, 14256 KiB

Open AccessEditor’s ChoiceArticle

Structural and Tribological Studies of “(TiC + WC)/Hardened Steel” PMMC Coating Deposited by Air Pulsed Plasma

by Yuliia Chabak, Vasily Efremenko, Vadym Zurnadzhy, Viktor Puchý, Ivan Petryshynets, Bohdan Efremenko, Victor Fedun, Kazumichi Shimizu, Iurii Bogomol, Volodymyr Kulyk and Dagmar Jakubéczyová

Metals 2022, 12(2), 218; https://doi.org/10.3390/met12020218 - 24 Jan 2022

Cited by 17 | Viewed by 2965

Abstract

The deposition of a thin (several tens of microns) protective coating in atmospheric conditions is a challenging task for surface engineering. The structural features and tribological properties of a particle-reinforced metal matrix composite coating synthesized on middle-carbon steel by air pulse-plasma treatments were [...] Read more.

The deposition of a thin (several tens of microns) protective coating in atmospheric conditions is a challenging task for surface engineering. The structural features and tribological properties of a particle-reinforced metal matrix composite coating synthesized on middle-carbon steel by air pulse-plasma treatments were studied in the present work. The 24–31 µm thick coating of “24 vol.% (TiC + WC)/Hardened steel matrix” was produced by 10 plasma pulses generated by an electro-thermal axial plasma accelerator equipped with a consumable cathode of novel design (low-carbon steel tube filled with “TiC/WC + Epoxy resin” mixture). The study included optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD, microhardness measurements, and dry “Ball-on-Plate” testing. The carbides were directly plasma-transferred to the substrate (steel of AISI 4145H grade) from the cathode without substantial melting. The hard (500–1044 HV) coating matrix consisted of 57 vol.% austenite (1.43 wt.% C) and 43 vol.% plate martensite was formed via carbon enrichment of steel from plasma flow. Additionally, a minor amount of oxide phases (TiO₂, WO₂, WO₃) were dispersed in the matrix. As compared to substrate, the coating had a lower coefficient of friction; its volumetric wear was decreased by 4.4 times when sliding against hardened steel ball and by 16 times when sliding against SiC ball. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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17 pages, 10090 KiB

Open AccessArticle

Corrosion Resistance of CoCrFeNiMn High Entropy Alloy Coating Prepared through Plasma Transfer Arc Claddings

by Pei-Hu Gao, Rui-Tao Fu, Bai-Yang Chen, Sheng-Cong Zeng, Bo Zhang, Zhong Yang, Yong-Chun Guo, Min-Xian Liang, Jian-Ping Li, Yong-Qing Lu, Lu Jia and Dan Zhao

Metals 2021, 11(11), 1876; https://doi.org/10.3390/met11111876 - 22 Nov 2021

Cited by 18 | Viewed by 1964

Abstract

High entropy alloy attracts great attention for its high thermal stability and corrosion resistance. A CoCrFeNiMn high-entropy alloy coating was deposited on grey cast iron through plasma transfer arc cladding. It formed fine acicular martensite near the grey cast iron, with columnar grains [...] Read more.

High entropy alloy attracts great attention for its high thermal stability and corrosion resistance. A CoCrFeNiMn high-entropy alloy coating was deposited on grey cast iron through plasma transfer arc cladding. It formed fine acicular martensite near the grey cast iron, with columnar grains perpendicular to the interface between the grey cast iron substrate and the cladding layer as well as dendrite in the middle part of the coatings. Simple FCC solid solutions present in the coatings which were similar to the powder’s structure. The coating had a microhardness of 300 ± 21.5 HV_0.2 when the cladding current was 80 A for the solid solution strengthening. The HEA coating had the highest corrosion potential of −0.253 V when the plasma current was 60 A, which was much higher than the grey cast iron’s corrosion potential of −0.708 V. Meanwhile, the coating had a much lower corrosion current density of 9.075 × 10⁻⁷ mA/cm² than the grey cast iron’s 2.4825 × 10⁻⁶ mA/cm², which reflected that the CoCrFeNiMn HEA coating had much better corrosion resistance and lower corrosion rate than the grey cast iron for single FCC solid solution phase and a relatively higher concentration of Cr in the grain boundaries than in the grains and this could lead to corrosion protection effects. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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18 pages, 7078 KiB

Open AccessArticle

Characterization of the Solid Particle Erosion of the Sealing Surface Materials of a Ball Valve

by Donghua Peng, Shaohua Dong, Zhiqiang Wang, Dongying Wang, Yinuo Chen and Laibin Zhang

Metals 2021, 11(2), 263; https://doi.org/10.3390/met11020263 - 04 Feb 2021

Cited by 11 | Viewed by 2953

Abstract

The ball valve is an essential piece of equipment in an oil and gas pipeline. The sand particles transported through the pipeline can cause erosion and wear to the ball valve, thus causing it to fail, leading to serious safety hazards. In this [...] Read more.

The ball valve is an essential piece of equipment in an oil and gas pipeline. The sand particles transported through the pipeline can cause erosion and wear to the ball valve, thus causing it to fail, leading to serious safety hazards. In this paper, the self-designed erosion experiment method was combined with computational fluid dynamics (CFD), while the Euler-Lagrange method was also introduced to optimize the Oka erosion model and Ford particle-wall rebound model. The erosion mechanism and characteristics of the ball valve sealing surface in gas-solid two-phase flow were simulated, while the erosion condition of the specimen was analyzed and compared when exposed to different factors, such as different particle velocities, impact angle, particle size, and specimen materials. The experimental data conformed well to the CFD erosion simulation data, verifying the accuracy of the CFD simulation analysis. The results indicated that the worn surface was caused by various wear mechanisms, while a “stagnation zone” was identified at the center of the specimen. The maximum erosion area, which was U-shaped, was also located at the center. The erosion rate increased in conjunction with an increase in the particle velocity and size, both of which failed to affect the erosion pattern. The erosion rate initially increased, after which it decreased with the impact angle, reaching the maximum value at an impact angle of 30°. This paper summarizes the erosion failure mechanism and characteristics in gas–solid two-phase flow and provides both technical support and a theoretical basis for the on-site maintenance of essential vulnerable parts in the pipeline, such as ball valves. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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24 pages, 9063 KiB

Open AccessFeature PaperArticle

Improved Procedures for Feature-Based Suppression of Surface Texture High-Frequency Measurement Errors in the Wear Analysis of Cylinder Liner Topographies

by Przemysław Podulka

Metals 2021, 11(1), 143; https://doi.org/10.3390/met11010143 - 12 Jan 2021

Cited by 19 | Viewed by 2171

Abstract

Studies on the effect of surface texture on cylinder liner wear is of great importance in many research areas due to the fact that a major part of the mechanical power losses in an engine are caused by friction in the piston-cylinder liner [...] Read more.

Studies on the effect of surface texture on cylinder liner wear is of great importance in many research areas due to the fact that a major part of the mechanical power losses in an engine are caused by friction in the piston-cylinder liner system. Interest from both manufacturers and customers in optimizing this mechanical system seems to be similar. The surface roughness of cylinder liners plays an important role in the control of tribological properties. Cylinder liner surface topography, which affects running-in duration, oil consumption, exhaust gas emissions and engine performance as well, was taken into detailed consideration in this paper. They were measured with a stylus (Talyscan 150) or non-contact—optical (Talysurf CCI Lite white light interferometer) equipment. Precise machining process and accurate measurement equipment may not provide relevant information about surface texture properties when the procedure of processing of received (raw) measured data is not selected appropriately. This work aims to compare various type of procedures for detection and reduction of some-frequency surface topography measurement errors (noise) and consider its influence on the results of wear analysis. It was found that assessments of some extracted areas (profiles) may be much more useful than the characterization of the whole of measured details when noise was defined. Moreover, applications of a commonly-used algorithm, available in the commercial software of the measuring equipment, for measurement errors suppression may be potentially decisive in the definition of measurement noise but, simultaneously, scrupulous attention should be paid if they are implemented adequately. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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14 pages, 6522 KiB

Open AccessArticle

Investigation on Ultrasonic Cavitation Erosion Behaviors of Al and Al-5Ti Alloys in the Distilled Water

by Jingtao Zhao, Zongming Jiang, Jingwen Zhu, Junjia Zhang and Yinglong Li

Metals 2020, 10(12), 1631; https://doi.org/10.3390/met10121631 - 04 Dec 2020

Cited by 9 | Viewed by 2109

Abstract

Al and Al-5Ti alloys were manufactured by an ultrasonic casting method with a new device, and their ultrasonic cavitation erosion behaviors of Al and Al-5Ti alloys in the distilled water were clarified. The damage mechanism was analyzed by macro photograph, scanning electronic micrograph [...] Read more.

Al and Al-5Ti alloys were manufactured by an ultrasonic casting method with a new device, and their ultrasonic cavitation erosion behaviors of Al and Al-5Ti alloys in the distilled water were clarified. The damage mechanism was analyzed by macro photograph, scanning electronic micrograph and three-dimensional morphology, and the results demonstrate that Al-5Ti alloys have better cavitation erosion resistance than Al in terms of the mass loss and the surface damage. The deformation mechanism of Al and Al-5Ti alloys under cavitation erosion is mainly dislocation slip, and the Al₃Ti phase enhances the cavitation erosion resistance of Al-5Ti alloys. In addition, the maximum depth of cavitation pits in the Al-5Ti sample is less than that in the Al sample for 31.3%. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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19 pages, 6357 KiB

Open AccessArticle

Application of Stray Magnetic Field for Monitoring the Wear Degree in Steel Components of the Lift Guide Rail System

by Poul Lonkwic, Tomasz Krakowski and Hubert Ruta

Metals 2020, 10(8), 1008; https://doi.org/10.3390/met10081008 - 27 Jul 2020

Cited by 7 | Viewed by 2763

Abstract

This paper presents the results of forced wear simulation of the friction lift guide rails. The forced wear in the case discussed is an effect of plastic strain of the guide rail surface due to emergency braking of the lift. For the purpose [...] Read more.

This paper presents the results of forced wear simulation of the friction lift guide rails. The forced wear in the case discussed is an effect of plastic strain of the guide rail surface due to emergency braking of the lift. For the purpose of qualitative and quantitative assessment of wear, the authors applied the numerical simulation of a stray magnetic field. Application of this method allowed evaluating the degree of wear based on the stray field changes. Application of this simulation method allowed obtaining satisfactory results of qualitative and quantitative assessment of the guide rail wear. The intention of this paper was to prove that the permanent magnetic field and the stray field can be applied for the efficient detection of the steel guide rail damages and to verify the possibility of making the quantitative assessment related to the guide rail wear degree versus the personal lift service life. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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25 pages, 11303 KiB

Open AccessArticle

Comparative Study on the Cavitation Erosion and Sliding Wear of Cold-Sprayed Al/Al₂O₃ and Cu/Al₂O₃ Coatings, and Stainless Steel, Aluminium Alloy, Copper and Brass

by Mirosław Szala, Leszek Łatka, Mariusz Walczak and Marcin Winnicki

Metals 2020, 10(7), 856; https://doi.org/10.3390/met10070856 - 28 Jun 2020

Cited by 56 | Viewed by 5330

Abstract

The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al₂O₃ and Cu/Al₂O₃ composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), [...] Read more.

The paper investigates the cavitation erosion (CE) and sliding wear (SW) resistance of cold-sprayed Al/Al₂O₃ and Cu/Al₂O₃ composites and studies them in relation to a set of metallic materials such as aluminium alloy (AlCu4Mg1), pure copper (Cu110), brass (CuZn40Pb2) and stainless steel (AISI 304). The coatings were deposited on stainless steel by low-pressure cold spray (LPCS) using Al (40 wt.%) and Cu (50 wt.%) blended with Al₂O₃ (60 and 50 wt.%, respectively) feedstocks. CE resistance was estimated by the stationary sample method according to the ASTM G32 standard. The SW test was conducted using a ball-on-disc tester with compliance to the ASTM G99 standard. Results obtained for the LPCS coatings show that the Cu/Al₂O₃ coating exhibits a denser structure but lower adhesion and microhardness than Al/Al₂O₃. The Al/Al₂O₃ and Cu/Al₂O₃ resistance to cavitation is lower than for bulk alloys; however, composites present higher sliding wear resistance to that of AlCu4Mg1, CuZn40Pb2 and stainless steel. The CE wear mechanisms of LPCS composites start at the structural discontinuities and non-uniformities. The cavitation erosion degradation mechanism of Al/Al₂O₃ relies on chunk material detachment while that of Cu/Al₂O₃ initiates by alumina removal and continues as layer-like Cu-metallic material removal. CE damage of metal alloys relies on the fatigue-induced removal of deformed material. The SW mechanism of bulk alloys has a dominant adhesive mode. The addition of Al₂O₃ successfully reduces the material loss of LPCS composites but increases the friction coefficient. Coatings’ wear mechanism has an adhesive-abrasive mode. In both CE and SW environment, the behaviour of the cold-sprayed Cu/Al₂O₃composite is much more promising than that of the Al/Al₂O₃. Full article

(This article belongs to the Special Issue Cavitation Erosion, Abrasive and Sliding Wear Behaviour of Metal-Based Structures)

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