Taguchi approach to erosion wear optimization of WC-10Co-4Cr sprayed austenitic steel subjected to equisized slurry

Abstract

Purpose This paper aims to optimize the erosion wear analysis of slurry impeller material. Stainless steel (SS-410) was used as the pump impeller material. This erosion test was established to influence the rotational speed, solid concentration, time period and particle size. Fly ash was used as the erodent material. Design/methodology/approach The erosion wear experiments were performed at different particle size, rotational speed, time duration and solid concentration (by weight). These tests were performed at four different speeds of 750, 1,000, 1,250 and 1,500 rpm, and the time durations of these experiments are 75, 120,165 and 210 min. For protective coating, high-velocity oxygen-fuel spray process was used for depositing WC-10Co-4Cr coating on stainless steel. To investigate the influence of controlled process parameters on slurry erosion wear of pump impeller material, Taguchi method was used. Findings Results show that significant improvement in erosion wear resistance has been observed by using WC-10Co-4Cr coating. The process parameters affecting the erosion wear loss were in following order: time > rpm > concentration > particle size. The means of signal-to-noise ratio of stainless steel SS410 with and without coating vary from 93.56 to 54.02 and from 86.02 to 48.18, respectively. Originality/value For the erosion wear rate of both uncoated and coated stainless steel, the most powerful influencing factor was identified as time. The erosion test reveals that the coating exhibits ductile erosion mechanism and shows better erosion wear resistance (approximately two times) compared to uncoated stainless steel.

Erosion wear analysis of HVOF coated Colmonoy-88 and Stellite-6 micron layers on pump impeller steel by using the Taguchi's approach

“…Large particles of erodent exhibits higher kinetic energy and impacting force as compared to small particles of erodent. This increase in impact energy exerted by increasing the particle size of erodent might be the main reason for such phenomenon (Singh et al , 2018a, 2018b).…”

“…Similarly, Figure 6(d) represents that specific erosion rate of coated surfaces increases with the increase in time duration. This may be due to the continuous bombardment of fly ash particles (erodents) over the coated surfaces (Chandel et al , 2012; Singh et al , 2018a, 2018b).…”

“…Hydraulic pumps are widely used for conveying slurry in coal and mining industries. Numerous mechanical components which deals with the solid-liquid mixtures such as pumps, impellers, pipes and casings gravely retrograded due to erosion wear (Gandhi et al , 1998; Grewal et al , 2013; Sharma et al , 2014; Singh et al , 2018a, 2018b). Basically, erosion wear is the mechanical loss of the mechanical components subjected to the impact of solid particles (erodent's) on its surface which is suspended in the liquid slurry.…”

“…Furthermore, the hardness and the erosion resistance of the different hydraulic parts can be improved by using various thermal spray coatings. Various factors like chemical and mechanical properties of coating powders, deposition or spraying conditions may determine the erosion resistance of the coatings (Singh et al , 2018a, 2018b). By using the HVOF technique, the bonding between the coating and the interface can be improved.…”

“…Various researchers have studied the erosion wear behaviors and mechanisms of the different coating combinations with the application of different coating techniques. Singh et al , 2018a, 2018b studied the tribological performance of tungsten coated pump impeller steel by using fly ash as erodent. They concluded that the erosion wear of tungsten coated pump impeller steel has improved as compared to uncoated steel.…”