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Abstract
This paper describes the water jet impingement erosion characteristics of titanium alloy (Ti6 Al4 V), Hadfield steel, laser hardened, plasma
nitrided and pack borided 12Cr steel along with most commonly used steels in hydro turbines. Round samples as per ASTM G73-98 were
tested for water jet impingement erosion study. While testing, in the incubation period, plasma nitrided and pack borided 12Cr steel
performed much better than 12Cr and 13Cr4Ni steels. Plasma nitrided 12Cr steel performed much better than pack borided 12Cr steel.
This is due to the integrity of plasma nitrided layers and their ability to absorb shocks due to jet impingement. During incubation as well
as in the long run, Hadfield steel and laser hardened 12Cr steel performed exceptionally well followed by 17Cr4Ni PH steel. Based on
this experimental study, a suitable criterion based on ultimate resilience (UR) for metallic materials and a composite modified resilience
(CMR) for hard metallic coatings has been discussed. Water jet impingement erosion test results along with the mechanical properties of
materials and coatings, and their scanning electron microstructural details are reported in this paper.
2002 Elsevier Science B.V. All rights reserved.
Keywords: Hydromachinery; Cavitation erosion; Plasma nitriding; Boronising; Laser hardening; Jet impingement erosion
1. Introduction
Despite tremendous developments in the hydroturbine
design and material improvements, liquid jet impingement
erosion still remains an unsolved problem. This phenomenon
occurs in various cases besides hydroturbine: (i) propellers,
hubs and rudders in case of ships, (ii) high speed pumps
of all types, (iii) regulators, valves and gate valves, (iv)
flow-measuring equipment like orifices, venturies, (v) sudden enlargements and bends, etc. It is essential to know the
mechanism of degradation of materials and identify a suitable material or coating to combat jet impingement erosion.
It has been assumed that the phenomenon of jet impingement
erosion and cavitation erosion is identical. For evaluating
the materials in cavitation erosion, ASTM G32, venturi and
rotating discs apparatus are used while for liquid jet impingement erosion, ASTM G73 is used. ASTM G32 is less expensive compared to other techniques. Due to the similarities in
the erosion pattern of both techniques, liquid jet impingement technique is preferred for coatings, elastomers and
brittle materials because various jet sizes can be used and
0043-1648/02/$ see front matter 2002 Elsevier Science B.V. All rights reserved.
PII: S 0 0 4 3 - 1 6 4 8 ( 0 2 ) 0 0 1 1 8 - 7
(UTS)2
2E
651
Diffused coatings or nitride layers produced either by chemical or physical vapour deposition are the techniques of
achieving such a composite structure as reported earlier [20].
Richman and McNaughton [16,17] have proposed a theory to correlate the cavitation erosion resistance based on
fatigue strength coefficient, f1 with an index of cyclic
stress resistance measurement. Explosive cladding of an
NiTi alloy with stainless steel is described as a cavitation erosion shield. The cavitation erosion mechanism was
confirmed by finite element modelling rather than by a
rational search for materials with requisite high fatigue
strength coefficient combined with a high cycling strain
hardening component. It was found that the NiTi alloy
has this property. Strong correlation was demonstrated
between cyclic deformation property rate and cavitation
erosion. The main determination of erosion resistance is
the fatigue strength coefficient (f1 ), which is a measure
of cyclic stress resistance. Material removal rate correlates well with the product of (f1 , n1 ), where n1 reflects
the cyclic strain resistance. The results are general over a
wide range of metal and alloys. Furthermore, this explains
why previous attempts to correlate cavitation erosion and
liquid droplet erosion behaviour with a single mechanical
or material property were unsuccessful. This is because
f 1 is strongly influenced by cyclic strain hardening.
Erosion behaviour is not simply related to any monotonic
property, such as true fracture stress or ultimate tensile stress.
The cavitation erosion studies based upon four cavitation
tunnels and four rotating disc apparatus, six vibratory test
rigs, one liquid jet and two cavitating jet techniques were
compared [1,2]. Theoretical and experimental predictions
of different materials for liquid impingement erosion at different velocities from different laboratories are also given.
The erosion resistance of different materials with a standard
material (stainless type 316) is also compared. The difference in the volume loss and standard deviation with regards
to their maximum erosion rate (depth of penetration) is also
reported. However, there are still gaps in the information
with regards to jet impingement erosion characteristics of
materials and coatings.
This paper presents data on water jet impingement erosion resistance of the various materials commonly used in
pumps and hydro turbines along with boronising, plasma
nitriding and surface hardening by laser. This also includes
erosion characteristics during initiation of damage. Based
upon the study, a suitable correlation between impingement
erosion resistance and mechanical properties was developed. The results of our recent findings regarding water jet
impingement erosion resistance of pack borided, plasma
nitrided and laser hardened 12Cr steel along with hydroturbine materials are reported.
652
Composition (wt.%)
12Cr AS
ST AS
13Cr4Ni
MDN AS
Hadfield
Ti6 Al4 V
Table 2
Mechanical properties of different coatings
Coatings
Fracture
toughness
(MPa m1/2 )
Plasma nitrided
12Cr steel
Pack boronised
12Cr steel
Laser hardened
12Cr steel
4.55.0
9421000
1.79
4.04.5
18002000
3.16
500650
0.945
Microhardness
(HV)
Composite
resilience
648700
65/35
12.25
2.44.5
1
545575
Cathode
48
40
653
Steels used for nitriding were 17Cr4Ni PH steel of composition 0.06% C, 15.67% Cr, 0.64% Mn, 0.27% Si, 4.25%
Ni, 0.04% P, 0.03% S, 3.6% Cu, and balance Fe and 12Cr
steel of composition, 0.12% C, 13.20% Cr, 0.55% Ni, 0.55%
Mn, 0.30% Si and balance Fe (refer Table 1).
2.4. Boronising
The boronising of the 12CR AS steel was done using a
pack cementation technique. The steel samples to be boronised were cleaned with acetone in ultrasonic equipment,
dried and packed in the boronising pack mixture in a steel
box. The steel box was sealed using a copper washer between the box and the cover. The packed steel box was
heated in an electric furnace (250 C/h), held at a temperature of 930 5 C for 4 h and then forced air-cooled.
After boronising, all the steel samples were thoroughly
cleaned before testing and were tempered at 650 C for
6 h. All these samples were subjected to XRD analysis.
This revealed the presence of FeB and Fe2 B phases. The
latter was dominant. The thickness of boronised steel was
measured using an optical microscope and was in the range
5560 m. An upper layer of 100 m, including 5560 m
of boronised layer, was removed by grinding. XRD analysis
of this sample was also carried out. The analysis did not
show the presence of metallic carbide, thus, eliminating the
chances of carburising while boronising.
2.5. Liquid impingement erosion resistance
of different coatings
A liquid jet impingement erosion test facility has been
designed and fabricated. After establishing the accuracy
of results similar to those reported in ASTM G73-98, this
facility has been used for testing of materials/coatings. The
test facility consists of a chamber of diameter 700 mm and
a round disc on which the test samples are fixed on the periphery. Details of the facility are given in Fig. 1. The disc is
rotated at 4575 rpm to obtain the test sample tangential velocity of 147.0 m/s. Two water jets impinge on the cylindrical test samples and cause impingement erosion. The cylindrical specimens were selected because the impingement
erosion on actual turbine blades occurs at the leading edge.
A precision balance to an accuracy of 0.1 mg was used
for measurement of weight loss occurring after a certain test
duration. The test duration was selected in such a way that
steady-state impingement erosion occurred. The accuracy of
the results has been confirmed using a reference 12Cr steel.
The standard deviation and resulting accuracy are also given.
The deviation and accuracy lie within specified accuracy
data available from different laboratories [8]. The results
have been plotted as commutative erosiontime curve on
co-ordinate of mean depth of erosion versus time. The depth
of erosion is calculated from the weight loss divided by the
density of the coatings and the materials. The test results are
given in Fig. 2.
654
Fig. 2. Volume loss vs. time for different materials and coatings.
4.24
20.166
12.70 40
12
7
6.375
0.785
100
90
78
21.25
1
30
655
656
657
658
sistance in comparison to plasma nitrided steel. The jet impingement erosion resistance for all the coated and uncoated
steels has been plotted with time and is given in Fig. 2. The
grain morphology of MDN AS, MDN PN, MDN HT
and ST HT is identical. MDN HT is the finest among
all these followed by MDN AS, MDN PN and ST HT.
Because of this MDN HT has performed much better than
the other steels. Crystal structure plays a crucial role in determining the liquid impingement similar to the cavitation
erosion resistance, as reported by Feller and Kharrazi [19]
in the case of cavitation erosion.
The plasma nitrided steels have eroded by smooth removal
of the hard layer without initiation of cracks and chipping of
the coating. The impingement erosion resistance of diffused
659
Yield strength
(N mm2 )
Ultimate tensile
(N mm2 )
Hardness
(HV)
Elongation
(%)
Ultimate resilience
(J cm3 )
Strain energy
(J cm3 )
Impact
strength (J)
12Cr AS
12Cr BN
12Cr PN
ST AS
ST HT
13/4 AS
MDN AS
MDN PN
MDN HT
Ti6 Al4 V
Hadfield
464.79
462.0
448.0
721.0
1134.0
813.2
863.49
1162.00
1305.09
850
369
720.45
666.0
740.00
876.0
1562.7
892.20
1224.28
1244.0
1448.68
874
833.3
200210
18002000
9421000
300350
450500
300310
365380
750900
450460
330350
202450a
26.98
18.0
13.87
23.17
15.6
14.8
13.44
12.63
13.04
13
47.5
1.23
1.05a
1.30a
1.83
5.78
1.90
3.577
3.69a
5.0
3.17
1.658.18
157.3
78.02
85.7
164.3
197.27
112.1
139.68
133.38
160.3
96.0
336.0
153
38.8
131
93.0
46.2
78.0
112.0
62.0
38
65
142
The 12Cr AS was in an annealed condition. The ST AS was in a forged condition and later on stress relieved at 250 C for 4 h. The ST HT was in
forged condition and heat treated at 950 c for 1 h followed by water quenching and later on stress relieved at 250 C for 4 h. The 13/4 AS was in as
cast condition and later on stress relieved at 250 C for 4 h. The MDN AS was in forged condition and later on stress relieved at 250 C for 4 h. The
MDN HT was in as cast condition and later on aged at 490 C for 3 h. The titanium alloy was in forged condition and later on heat treated at 950 C
for 1 h followed by water quenching and aged to 535 C for 6 h.
a Samples showed reduction in UTS, elongation and impact strength after coating. This has earlier been reported in case of boronising [27].
Table 4
Mechanical properties of different materials
Materials
Hardness
(HV)
Modified
resilience (HV)
Impact
strength (J)
12Cr AS
ST AS
ST HT
13/4 AS
MDN AS
MDN HT
Ti6 Al4 V
Hadfield
200210
300350
450500
300310
365380
450460
330350
202450a
0.369
0.712
1.86
0.68
1.13
1.68
1.29
0.4282.08
153
93.0
46.2
78.0
112.0
38
65
142
660
4. Conclusions
Table 5
Incubation period of different coatings/materials
Coatings/materials
12Cr AS
ST AS
13/4 AS
12Cr BN
Ti6 Al4 V
MDN PN
MDN AS
ST HT
12Cr PN
MDN HT
12Cr LH
Hadfield
1
2
3
4
4
4
4
5
5
7
>7
>7
Table 6
Volume loss and ranking of different coatings/materials after 7 h
Coating/materials
Ranking
12Cr AS
ST AS
13/4AS
ST HT
12Cr BN
12Cr PN
Ti6 Al4 V
MDN PN
MDN AS
MDN HT
12Cr LH
Hadfield
12
11
10
9
8
7
6
5
4
3
2
1
43.46
7.58
2.37
1.77
1.34
1.26
1.16
0.30
0.30
0.09
0.01
0
Acknowledgements
The authors are thankful to Mr. Pankaj Joshi for his help
in experimentation. Authors are also thankful to the management of Corporate Research & Development Division,
661