Improving Erosion Resistance of Hydroturbine Steel Using Friction Stir Processing
01 Oct 2014-Journal of Tribology-transactions of The Asme (American Society of Mechanical Engineers)-Vol. 136, Iss: 4, pp 041102
About: This article is published in Journal of Tribology-transactions of The Asme.The article was published on 2014-10-01. It has received 14 citations till now. The article focuses on the topics: Friction stir processing.
Citations
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TL;DR: In this paper, the authors studied the slurry erosion resistance of 13Cr4Ni stainless steel after thermo-mechanical processing using Gleeble® 3800 simulator.
Abstract: Slurry erosion resistance of 13Cr4Ni stainless steel is studied after thermo-mechanical processing. Thermo-mechanical processing was performed using thermo-mechanical simulator Gleeble® 3800. Deformation strain rates of 0.001 and 10 s −1 were used at 950 °C and 1050 °C. Refined prior austenite grain size and lath packets of martensite obtained after thermo-mechanical processing were studied using optical micrographs. The thermo-mechanically processed specimens showed higher slurry erosion resistance as compared to the as-received stainless steel. Specimen thermo-mechanically processed at 950 °C using a strain rate of 0.001 s −1 showed the best resistance to slurry erosion. The mechanism of erosion is discussed by correlating with microstructure and mechanical properties. Refined prior austenite grain size and martensite lath packets resulting from the thermo-mechanical processing are responsible for the enhanced slurry erosion resistance of the processed specimens.
25 citations
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TL;DR: In this article, WC-10Co-4Cr coating was applied to the surface of F6NM stainless steel by high-velocity oxygen-fuel spraying and the slurry erosion behavior of the matrix and coating was examined at different rotational speeds using a self-made machine.
Abstract: WC-10Co-4Cr coating was applied to the surface of F6NM stainless steel by high-velocity oxygen-fuel spraying. The slurry erosion behavior of the matrix and coating was examined at different rotational speeds using a self-made machine. This experiment effectively simulates real slurry erosion in an environment with high silt load. At low velocity (<6 m/s), the main failure mechanism was cavitation. Small bubbles acted as an air cushion, obstructing direct contact between sand and the matrix surface. However, at velocity above 9 m/s, abrasive wear was the dominant failure mechanism. The results indicate that WC-10Co-4Cr coating significantly improved the slurry resistance at higher velocity, because it created a thin and dense WC coating on the surface.
23 citations
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TL;DR: In this article, a copper-based surface composite was fabricated through dispersing hybrid composite particles onto its surface through friction stir processing (FSP) technique, and the composite particles were then used for fabrication.
Abstract: In this research, a copper based surface composite was fabricated through dispersing hybrid composite particles onto its surface through friction stir processing (FSP) technique. Optical micrograph...
15 citations
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TL;DR: In this article, a low carbon steel (Grade A) was subjected to friction stir processing (FSP), and the effect of FSP on the microstructure and mechanical properties was investigated systematically.
Abstract: A low carbon steel (Grade A) was subjected to friction stir processing (FSP), and the effect of FSP on the microstructure and mechanical properties was investigated systematically It was found that two distinct zones called stir zone (SZ) and heat-effected zone (HAZ) were formed during FSP The SZ and HAZ consist mainly of ferrite, widmanstatten ferrite, ferrite+cementite aggregates, and martensite FSP considerably refined the microstructure of the steel by means of dynamic recrystallization mechanism and formed a volumetric defect-free basin-like processed region The ferritic grain size of the steel decreased from 25 µm in the coarse-grained state to about 3 µm in the fine-grained state, and the grains formed were separated mostly by high angle of misorientation with low density of dislocations This microstructural evolution brought about a considerable increase in both hardness and strength values without a considerable decrease in ductility Ultrafine-grained microstructure formed around and just beneath the pin increased the hardness of the steel from 140 Hv03 to about 245 Hv03 However, no hardness uniformity was formed throughout the processed zone due to the changes in deformation- and temperature-induced microstructure Both yield and tensile strength values of processed zone increased from 256 and 435 MPa to about 334 and 525 MPa, respectively
15 citations
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TL;DR: In this paper, high strain-rate deformation of austenitic steel, SS316L, was performed by innovative submerged friction stir processing technique, which showed significant grain refinement for the sample processed under submerged conditions.
Abstract: Marine and off-shore components including propellers, pumps, valves, pipelines and other submerged surfaces are subjected to severe degradation by erosion. Impingement of solid particles mixed in a liquid, referred as slurry, leads to significant material loss and shortens the life span of components. Tailoring the surface properties of materials is an economical way for addressing their degradation. Surface modification through high strain-rate deformation is widely used to enhance functional properties of materials. However, surface modification, particularly at low temperature, is extremely challenging for high strength materials such as stainless steel and has not been investigated comprehensively so far. In the present work, high strain-rate deformation of austenitic steel, SS316L, was performed by innovative submerged friction stir processing technique. For comparative studies, friction stir processing was also performed under ambient cooling conditions. Electron back scatter diffraction studies showed significant grain refinement for the sample processed under submerged conditions. The erosion behavior of as-received and processed steel was investigated using slurry erosion tests. Erosion tests were performed at constant impact velocity of 20 m/s and particle size, while varying the impingement angles. The sample processed under submerged conditions showed nearly two times higher erosion resistance compared to as-received steel. The enhancement in erosion resistance is explained using structural rejuvenation achieved at high strain-rate deformation. All the samples showed similar erosion mechanisms with micro-cutting and ploughing being evident at acute angles and platelet mechanism at normal impingement angle. Erosion phenomena showed a strong correlation with material's hardness at oblique impingement angle while, erosion behavior at normal impingement is explained by the flow work given as hardness to elastic modulus ratio. The study provides fundamental insights into material design for advanced structural applications.
6 citations
References
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Book•
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TL;DR: Friction stir welding (FSW) is a relatively new solid-state joining process that is used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding as discussed by the authors.
Abstract: Friction stir welding (FSW) is a relatively new solid-state joining process. This joining technique is energy efficient, environment friendly, and versatile. In particular, it can be used to join high-strength aerospace aluminum alloys and other metallic alloys that are hard to weld by conventional fusion welding. FSW is considered to be the most significant development in metal joining in a decade. Recently, friction stir processing (FSP) was developed for microstructural modification of metallic materials. In this review article, the current state of understanding and development of the FSW and FSP are addressed. Particular emphasis has been given to: (a) mechanisms responsible for the formation of welds and microstructural refinement, and (b) effects of FSW/FSP parameters on resultant microstructure and final mechanical properties. While the bulk of the information is related to aluminum alloys, important results are now available for other metals and alloys. At this stage, the technology diffusion has significantly outpaced the fundamental understanding of microstructural evolution and microstructure–property relationships.
4,233 citations
Book•
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01 Jan 1992
TL;DR: In this paper, surface topography and surfaces in contact are discussed, as well as surface engineering in tribology, materials for bearings and sliding wear by hard particles, friction and friction.
Abstract: Preface * Introduction * Surface topography and surfaces in contact * Friction * Lubricants and lubrication * Sliding wear * Wear by hard particles * Wear and design * Surface engineering in tribology * Materials for bearings * Author index * Subject index.
2,558 citations
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TL;DR: In this paper, the authors discussed some aspects of the fluid flow conditions which may lead to erosion and then analyzed the mechanism of material removal for ductile and brittle materials for both types of materials.
Abstract: The amount of surface material eroded by solid particles in a fluid stream depends on the conditions of fluid flow and on the mechanism of material removal. The paper first discusses some aspects of the fluid flow conditions which may lead to erosion and then analyses the mechanism of material removal for ductile and brittle materials. For ductile materials it is possible to predict the manner in which material removal varies with the direction and velocity of the eroding particles. The numerical magnitude of the erosion cannot be predicted with accuracy but does correlate with data from metal cutting tests. For brittle materials the conditions leading to initial cracking are deduced and ways of predicting the material removal are discussed. It was not found possible to develop an analysis as detailed as that for ductile materials. In addition, the influence of the properties of the abrasive particle on erosion is briefly considered.
1,231 citations
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TL;DR: In this article, a comprehensive computational study was undertaken to identify the extent to which elasto-plastic properties of ductile materials could be determined from instrumented sharp indentation and to quantify the sensitivity of such extracted properties to variations in the measured indentation data.
Abstract: A comprehensive computational study was undertaken to identify the extent to which elasto- plastic properties of ductile materials could be determined from instrumented sharp indentation and to quantify the sensitivity of such extracted properties to variations in the measured indentation data. Large deformation finite element computations were carried out for 76 different combinations of elasto-plastic properties that encompass the wide range of parameters commonly found in pure and alloyed engineering metals: Young's modulus, E, was varied from 10 to 210 GPa, yield strength, sy, from 30 to 3000 MPa, and strain hardening exponent, n, from 0 to 0.5, and the Poisson's ratio, n, was fixed at 0.3. Using dimensional analysis, a new set of dimensionless functions were constructed to characterize instrumented sharp indentation. From these functions and elasto-plastic finite element computations, analytical expressions were derived to relate inden- tation data to elasto-plastic properties. Forward and reverse analysis algorithms were thus established; the forward algorithms allow for the calculation of a unique indentation response for a given set of elasto-plastic properties, whereas the reverse algorithms enable the extraction of elasto-plastic properties from a given set of indentation data. A representative plastic strain er was identified as a strain level which allows for the construction of a dimensionless description of indentation loading response, independent of strain hardening exponent n. The proposed reverse analysis provides a unique solution of the reduced Young's modulus E*, a representative stress sr, and the hardness pave. These values are somewhat sensitive to the experimental scatter and/or error commonly seen in instrumented indentation. With this information, values of sy and n can be determined for the majority of cases considered here, provided that the assumption of power law hardening adequately represents the full uniaxial stress-strain response. These plastic properties, however, are very strongly influenced by even small variations in the parameters extracted from instrumented indentation experiments. Comprehensive sensitivity analyses were carried out for both forward and reverse algorithms, and the computational results were compared with experimental data for two materials. 2001 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.
1,162 citations
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TL;DR: Friction stir welding (FSW) is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components.
Abstract: Friction stir processing (FSP), developed based on the basic principles of friction stir welding (FSW), a solid-state joining process originally developed for aluminum alloys, is an emerging metalworking technique that can provide localized modification and control of microstructures in near-surface layers of processed metallic components. The FSP causes intense plastic deformation, material mixing, and thermal exposure, resulting in significant microstructural refinement, densification, and homogeneity of the processed zone. The FSP technique has been successfully used for producing the fine-grained structure and surface composite, modifying the microstructure of materials, and synthesizing the composite and intermetallic compound in situ. In this review article, the current state of the understanding and development of FSP is addressed.
795 citations
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