Solid-particle erosion behavior of cast alloys used in the mining industry

Abstract

The erosive-wear response of five commercial ferrous-based cast alloys used for crushing was examined in this study. The microstructures of the alloys were modified to elucidate the effect of microstructural features on wear. Erosion tests were conducted using aluminum oxide particles (90–125 μm) at 70 m/s and a normal impact angle (90°). The worn surfaces were characterized by scanning electron microscopy and 3D non-contact laser profilometry. It is found that (i) a pearlitic structure exhibiting a greater plastic deformation than both bainitic and martensitic structures shows the greatest resistance to erosive wear at normal impact and (ii) the fracture characteristics of carbide and graphite particles plays an important role in determining the erosion wear behavior of the cast alloy matrices.

Keywords

mining tools / microstructure / solid particle impact / erosion / characterization

References

[1] da Cunha E.R., de Carvalho R.M., Tavares L.M. Simulation of solids flow and energy transfer in a vertical shaft impact crusher using DEM. Miner. Eng., 2013, 43–44, 85.

[2] Kwon J., Cho H., Mun M., Kim K. Modeling of coal breakage in a double-roll crusher considering the reagglomeration phenomena. Powder Technol., 2012, 232, 113.

[3] Lindqvist M., Evertsson C.M. Development of wear model for cone crushers. Wear, 2006, 261(3-4): 435.

[4] Zum Gahr K.H. Microstructure and Wear of Materials, 1987 531.

[5] Lindqvist M., Evertsson C.M. Liner wear in jaw crushers. Miner. Eng., 2003, 16(1): 1.

[6] Sare I.R., Mardel J.I., Hill A.J. Wear-resistant metallic and elastomeric materials in the mining and mineral processing industries: an overview. Wear, 2001, 250(1-12): 1.

[7] Chauhan A.K., Goel D.B., Prakash S. Solid particle erosion of 13Cr-4Ni and 21Cr-4Ni-N steels. J. Alloys Compd., 2009, 467(1-2): 459.

[8] Yildizli K., Karamis M.B., Nair F. Erosion mechanisms of nodular and gray cast irons at different impact angles. Wear, 2006, 261(5-6): 622.

[9] Al-Bukhaiti M.A., Ahmed S.M., Badran F.M.F., Emara K.M. Effect of impingement angle on slurry erosion behaviour and mechanisms of 1017 steel and high-chromium white cast iron. Wear, 2007, 262(9-10): 1187.

[10] Akbarzadeh E., Elsaadawy E., Sherik A.M., Spelt J.K., Papini M. The solid particle erosion of 12 metals using magnetite erodent. Wear, 2012, 282–283, 40.

[11] O’Flynn D.J., Bingley M.S., Bradley M.S.A., Burnett A.J. A model to predict the solid particle erosion rate of metals and its assessment using heat-treated steels. Wear, 2001, 248(1-2): 162.

[12] Totten G.E. Steel Heat Treatment Handbook, 2006 2 140.

[13] Birbasar O., Türedi E., Atapek S.H., Zeren M. Dry sliding wear behaviour of cast roller materials. Int. J. Surf. Sci. Eng., 2015, 9(2-3): 253.

[14] Polat S., Türedi E., Atapek S.H., Köseoglu M. Wear behaviour of heat treated 100Cr₆ steels. Mater. Test., 2013, 55(4): 290.

[15] Atapek S.H., Polat S. A study of wear of high-chromium cast iron under dry friction. Met. Sci. Heat Treat., 2013, 55(3): 181.

[16] Levy A.V. The solid particle erosion behavior of steel as a function of microstructure. Wear, 1981, 68(3): 269.

[17] Hung F.Y., Chen L.H., Lui T.S. A study on erosion of upper bainitic ADI and PDI. Wear, 2006, 260(9-10): 1003.

[18] Hsu C.H., Chiu S.C., Lu J.K., Shih Y.H. Effects of eutectic carbide content on erosion behaviors in ductile cast irons. Mater. Trans., 2004, 45(2): 577.

[19] Stevenson A.N.J., Hutchings I.M. Wear of hardfacing white cast irons by solid particle erosion. Wear, 1995, 186–187(1): 150.

[20] Dai W.S., Chen L.H., Lui T.S. A study on SiO₂ particle erosion of flake graphite and spheroidal graphite cast irons. Wear, 2000, 239(1): 143.

[21] ISO 25178: Geometric Product Specifications (GPS) - Surface Texture: Areal, International Standardization Organization, 2012.

[22] Levin B.F., Vecchio K.S., DuPont J.N., Marder A.R. Modeling solid-particle erosion of ductile alloys. Metall. Mater. Trans. A, 1999, 30(7): 1763.

[23] Yang J., Wang T.S., Zhang B., Zhang F.C. Sliding wear resistance and worn surface microstructure of nanostructured bainitic steel. Wear, 2012, 282–283, 81.

[24] Lee K.M., Polycarpou A.A. Wear of conventional pearlitic and improved bainitic rail steels. Wear, 2005, 259(1-6): 391.

[25] Clayton P., Devanathan R. Rolling/sliding wear behavior of a chromium?molybdenum rail steel in pearlitic and bainitic conditions. Wear, 1992, 156(1): 121.

[26] Sundararajan G., Roy M. Solid particle erosion behaviour of metallic materials at room and elevated temperatures. Tribol. Int., 1997, 30(5): 339.

[27] Suchánek J., Kuklík V., Zdravecká E. Influence of microstructure on erosion resistance of steels. Wear, 2009, 267(11): 2092.

[28] Buni S.Y., Raman N., Seshan S. Effect of structural features on erosion resistance of cast irons. Tribol. Lett., 1996, 2(1): 99.