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

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Corrosion and Protection".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 26295

Special Issue Editor


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Guest Editor
Department of Materials Engineering, Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: cavitation erosion; abrasion; tribology; failure analysis; additive manufacturing; thermal spraying; thin films; shot peening; ion implantation; hardfacing; welding; cobalt alloys; nickel alloys; cermets; metal matrix composites; stainless and structural steels; fatigue; mechanical properties; microstructure
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Special Issue Information

Dear Colleagues,

It is my honor to announce a Special Issue of Metals (IF 2.117) entitled “Cavitation Erosion, Abrasive, and Sliding Wear Behavior of Metal-Based Structures”. The Issue will include experimental or numerical papers and review manuscripts regarding advances in the wear resistance and development of metal-based structures (metallic materials). The content of this Special Issue is addressed to a broad group of scientists and engineers systematically working in the field of wear prevention of machine parts and components manufactured with metallic materials.

The literature includes systematic studies of the wear behavior and phenomena responsible for materials degradation resistance. Overall, from the broad range of the deterioration processes, tribological wear, namely sliding and abrasive wear, is the dominant type of engineering material degradation. Cavitation erosion is a unique wear process that still is not entirely understood. Even though the literature on the subject explains the general factors influencing both cavitation erosion and tribological wear of materials, the continuous development of metal-based structures fabrication, processing, and treatment technology demands systematic reporting on the advances in the wear properties of metallic materials. From both the scientific and engineering points of view, the wear of metallic components must be minimized to improve their reliability. The engineering industry is demanding metal-based structures that perform well in terms of cavitation erosion or tribological wear environments or optimally to both. First, to manage that task, material wear mechanisms should be understood. To facilitate the selection and design of wear-resistant materials, computer simulation, numerical calculations, or artificial neural networks can be employed. Therefore, papers containing the experimental and numerical results combined with the effect of material properties on the cavitation, abrasion, or sliding wear resistance are especially welcome.

This Special Issue is focused on the studies related to cavitation erosion, abrasive or sliding resistance, and wear mechanisms of metal-based structures: metal alloys, sinters, hardfacings, thermally sprayed deposits, thin films, composites, and additive manufactured metal structures, and many more. Papers focused on wear improvement via microstructural properties modification, surface layer treatment, and the deposition of wear-resistant coatings onto a metal-based substrate are encouraged. The scientific papers contained in this Special Issue will provide new knowledge in the fields of materials science and mechanical engineering.

This Special Issue is open for submissions, and welcomes original research contributions and review articles highlighting recent advances and future directions in the fields of cavitation erosion, and abrasive and sliding wear behavior of metal-based structures.

Dr. Mirosław Szala
Guest Editor

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Keywords

  • Cavitation erosion
  • Abrasion and sliding wear
  • Tribology and friction
  • Wear behavior and wear mechanisms
  • Additive manufacturing technology
  • Hardfacing and overlay welding
  • Surface engineering and laser surfacing
  • Thermal spraying
  • PVD thin-film deposition
  • Ion implantation
  • Shot peening and cold working processing
  • Artificial neural network
  • Computational simulations

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Published Papers (8 papers)

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Editorial

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2 pages, 175 KiB  
Editorial
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 3 | Viewed by 1517
Abstract
The literature includes systematic studies of the wear behavior and phenomena responsible for a material’s degradation resistance [...] Full article

Research

Jump to: Editorial

24 pages, 14256 KiB  
Article
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 24 | Viewed by 3384
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
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17 pages, 10090 KiB  
Article
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 22 | Viewed by 2362
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 HV0.2 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
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18 pages, 7078 KiB  
Article
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 - 4 Feb 2021
Cited by 15 | Viewed by 3422
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
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24 pages, 9063 KiB  
Article
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 24 | Viewed by 2505
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
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14 pages, 6522 KiB  
Article
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 - 4 Dec 2020
Cited by 9 | Viewed by 2500
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
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19 pages, 6357 KiB  
Article
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 3010
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
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25 pages, 11303 KiB  
Article
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 62 | Viewed by 6006
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/Al2O3 composite is much more promising than that of the Al/Al2O3. Full article
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