Abstract
In this research, we utilize image processing to analyze surfaces acquired from slurry-erosion tests carried out on AISI 5117 steel at various velocities and impact angles of 30 deg and 90 deg. The fractal and wavelet decomposition transform are two analysis tools that are particularly promising in this regard. These can be used to extract metrics that characterize slurry erosion in the same way that erosion rate is characterized. The study found that for a higher velocity of 15 m/s and a 30-deg impact angle, the fractal value was larger, irrespective of magnification. The fractal value is also in a positive linear regression with magnification. The extracted features of wavelet analysis were not distinctive for slurry-erosion behavior. The role of impact velocity in creating erosion damage is related to the variety of erosion mechanisms that are dependent on the particles’ kinetic energy. Microscopic examinations of damaged surfaces revealed that extruded lips indentation was the major mechanism of erosion, which occurred at 5 m/s speed and 30-deg impingement angle. Ploughing was proved that it was the predominant erosion mechanism at high velocity. Hence, the impact velocity determines the length of the wear tracks created by the ploughing mechanism.
Issue Section:
Friction and Wear
Keywords:
slurry erosion,
AISI 5117 steel,
impact velocity,
image analysis,
fractal,
wavelet,
erosion mechanism,
wear mechanisms
Topics:
Erosion,
Fractals,
Particulate matter,
Slurries,
Steel,
Wavelets,
Wear,
Image processing,
Magnification
References
1.
Miller
, J. E.
, 1992
, “Slurry Erosion. In: ASM Handbook,” Friction, Lubrication, and Wear Technology
, Vol. 18
, ASM International
, Material Park, OH
, pp. 233
–235
.2.
Fang
, O.
, Sidky
, P. S.
, and Hocking
, M. G.
, 1998
, “Microripple Formation and Removal Mechanism of Ceramic Materials by Solid-Liquid Slurry Erosion
,” Wear
, 223
(1–2
), pp. 93
–101
. 3.
Lathabai
, S.
, and Pender
, D. C.
, 1995
, “Microstructure Influence in Slurry Erosion of Ceramics
,” Wear
, 189
(1–2
), pp. 122
–135
. 4.
Li
, Y.
, Burstein
, G. T.
, and Hutchings
, I. M.
, 1995
, “The Influence of Corrosion on the Erosion of Aluminum by Aqueous Silica Slurries
,” Wear
, 186–187
, pp. 515
–522
. 5.
Iwai
, Y.
, and Nambu
, K.
, 1997
, “Slurry Wear Properties of Pump Lining Materials
,” Wear
, 210
(1–2
), pp. 211
–219
. 6.
Tsai
, W.
, Humphrey
, J. A. C.
, Cornet
, I.
, and Levy
, A. V.
, 1981
, “Experimental Measurement of Accelerated Erosion in a Slurry Pot Tester
,” Wear
, 68
(3
), pp. 289
–303
. 7.
Stanisa
, B.
, and Ivusic
, V.
, 1995
, “Erosion Behaviour and Mechanisms for Steam Turbine Rotor Blades
,” Wear
, 186–187
, pp. 395
–400
. 8.
Humphrey
, J. A. C.
, 1990
, “Fundaments of Fluid Motion in Erosion by Solid Particle Impact
,” Int. J. Heat Fluid Flow
, 11
(3
), pp. 170
–195
. 9.
Clark
, H. M.
, 1992
, “The Influence of the Flow Field in Slurry Erosion
,” Wear
, 152
(2
), pp. 223
–240
. 10.
Alam
, T.
, Aminul Islam
, M.
, and Farhat
, Z. N.
, 2016
, “Slurry Erosion of Pipeline Steel: Effect of Velocity and Microstructure
,” ASME J. Tribol.
, 138
(2
), p. 021604
. 11.
Singh
, J.
, and Singh
, A. P.
, 2019
, “Effect of Jet Velocity and Angle of Impact on Slurry Erosion Rate of Steels and Super Alloys
,” J. Com. Theory
, XII
(VII
), pp. 529
–536
.12.
Reyes-Mojena
, M. Á.
, Sánchez-Orozco
, M.
, Carvajal-Fals
, H.
, Zamora
, R. S.
, and Camello-Lima
, C. R.
, 2017
, “A Comparative Study on Slurry Erosion Behavior of HVOF Sprayed Coatings
,” Dyna
, 84
(202
), pp. 239
–246
. 13.
Yu
, B.
, Li
, D. Y.
, and Grondin
, A.
, 2013
, “Effects of the Dissolved Oxygen and Slurry Velocity on Erosion–Corrosion of Carbon Steel in Aqueous Slurries with Carbon Dioxide and Silica Sand
,” Wear
, 302
(1–2
), pp. 1609
–1614
. 14.
Abd-Elrhman
, Y. M.
, Abouel-Kasem
, A.
, Ahmed
, S. M.
, and Emara
, K. M.
, 2014
, “Stepwise Erosion as a Method for Investigating the Wear Mechanisms at Different Impact Angles in Slurry Erosion
,” ASME J. Tribol.
, 136
(2
), p. 021608
. 15.
Abd-Elrhman
, Y. M.
, Abouel-Kasem
, A.
, Emara
, K. M.
, and Ahmed
, S. M.
, 2014
, “Effect of Impact Angle on Slurry Erosion Behavior and Mechanisms of Carburized AISI 5117 Steel
,” ASME J. Tribol.
, 136
(1
), p. 011106
. 16.
Al-Bukhaiti
, M. A.
, Ahmed
, S. M.
, Badran
, F. M. F.
, and Emara
, K. M.
, 2007
, “Effect of Impact Angle on Slurry Erosion Behavior and Mechanisms of 1017 Steel and High-Chromium White Cast Iron
,” Wear
, 262
(9–10
), pp. 1187
–1198
. 17.
Sapate
, S. G.
, and Haque
, N.
, 2011
, “Effect of Microstructure on Slurry Erosion Behaviour of Weld Hard Facing Alloys
,” J. Mater. Des. Appl.
, 225
(I
), pp. 49
–59
.18.
Al-Bukhaiti
, M. A.
, Abouel-Kasem
, A. A.
, Emara
, K. M.
, and Ahmed
, S. M.
, 2017
, “A Study on Slurry Erosion Behavior of High Chromium White Cast Iron
,” ASME J. Tribol.
, 139
(4
), p. 041102
. 19.
Saleh
, B.
, Abouel-Kasem
, A.
, and Ahmed
, S. M.
, 2015
, “Effect of Surface Properties Modification on Slurry Erosion-Corrosion Resistance of AISI 5117 Steel
,” ASME J. Tribol.
, 137
(3
), p. 031105
. 20.
Aso
, S.
, Goto
, S.
, Komatsu
, Y.
, Liu
, W.
, and Liu
, C.
, 1999
, “Slurry Erosion of Fe-15 Mass % 25 Mass % Cr-C-B Eutectic Alloys
,” Wear
, 233–235
, pp. 160
–167
. 21.
Lindsley
, B. A.
, and Marder
, A,R
, 1999
, “The Effect of Velocity on the Solid Particle Erosion Rate of Alloys
,” Wear
, 225–229
, pp. 510
–516
. 22.
Clark
, H. M.
, 1991
, “On the Impact Rate and Impact Energy of Particles in a Slurry pot Erosion Tester
,” Wear
, 147
(1
), pp. 165
–183
. 23.
Lin
, H. C.
, Wu
, S. K.
, and Yeh
, C. H.
, 2001
, “A Comparison of Slurry Erosion Characteristics of TiNi Shape Memory Alloys and SUS 304 Stainless Steel
,” Wear
, 249
(7
), pp. 557
–565
. 24.
Wong
, K. K.
, and Clark
, H. M.
, 1993
, “A Model of Particle Velocities and Trajectories in Slurry Erosion pot Tester
,” Wear
, 160
(1
), pp. 95
–104
. 25.
Hojo
, H.
, Tsuda
, K.
, and Yabu
, T.
, 1986
, “Erosion Damage of Polymeric Materials by Slurry
,” Wear
, 112
(1
), pp. 17
–28
. 26.
Levy
, A. V.
, and Hickey
, G.
, 1987
, “Liquid Solid Particle Slurry Erosion of Steels
,” Wear
, 117
(2
), pp. 129
–146
. 27.
Lin
, F. Y.
, and Shao
, H. S.
, 1991
, “Effect of Impact Velocity on Slurry Erosion and a New Design of Slurry Erosion Tester
,” Wear
, 143
(2
), pp. 231
–240
. 28.
Levy
, A. V.
, Jee
, N.
, and Yau
, P.
, 1987
, “Erosion Steel in Coal-Solved Slurries
,” Wear
, 117
(2
), pp. 115
–127
. 29.
Elkholy
, A.
, 1983
, “Prediction of Abrasive Wear for Slurry Pump Materials
,” Wear
, 84
(1
), pp. 39
–49
. 30.
Stack
, M. M.
, and Pungwiwat
, N.
, 1998
, “A Note on the Construction of Materials Performance Maps for Resistance to Erosion in Aqueous Slurries
,” Wear
, 215
(1–2
), pp. 67
–76
. 31.
Clark
, H. M.
, 1991
, “A Comparison of the Erosion Rate of Casing Steels by Sand/oil Suspensions
,” Wear
, 150
(1–2
), pp. 217
–230
. 32.
El-Alej
, M. E.
, 2014
, “Monitoring Sand Particle Concentration in Multiphase Flow Using Acoustic Emission Technology
,” PhD thesis
, Cranfield University
.33.
Abouel-Kasem
, A.
, 2011
, “Particle Size Effects on Slurry Erosion of 5117 Steels
,” ASME J. Tribol.
, 133
(1
), p. 014502
. 34.
Droubi
, M. G.
, and Reuben
, R. L.
, 2016
, “Monitoring Acoustic Emission (AE) Energy of Abrasive Particle Impacts in a Slurry Flow Loop Using a Statistical Distribution Model
,” Applied Acoustics
, 113
, pp. 202
–209
. 35.
Buttle
, D. J.
, and Scruby
, C. B.
, 1990
, “Characterization of Particle Impact by Quantitative Acoustic Emission
,” Wear
, 137
(1
), pp. 63
–90
. 36.
Droubi
, M. G.
, Reuben
, R. L.
, and White
, G.
, 2012
, “Acoustic Emission (AE) Monitoring of Abrasive Particle Impacts on Carbon Steel
,” Proc IMechE, Part E, J Process Mech Eng.
, 226
(3
), pp. 187
–204
. 37.
Ukpai
, I.
, Barker
, R.
, Hu
, X.
, and Neville
, A.
, 2013
, “Exploring the Erosive Wear of X65 Carbon Steel by Acoustic Emission Method
,” Wear
, 301
(1–2
), pp. 370
–382
. 38.
Wild
, G.
, and Hinckley
, S.
, 2007
, “Fiber Bragg Grating Sensors for Acoustic Emission and Transmission Detection Applied to Robotic NDE in Structural Health Monitoring
,” Proceedings of the IEEE Sensors Applications Symposium
, March
, pp. 1
–6
.39.
Abouel-Kasem
, A.
, Al-Bukhaiti
, M. A.
, Ahmed
, S. M.
, and Emara
, K. M.
, 2009
, “Fractal Characterization of Slurry Eroded Surfaces at Different Impact Angles
,” ASME J. Tribol.
, 131
(3
), p. 031601
. 40.
Abouel-Kasem
, A.
, Alturki
, F. A.
, and Ahmed
, S. M.
, 2011
, “Fractal Analysis of Cavitation Eroded Surface in Dilute Emulsions,”
ASME J. Tribol
, 133
(4
), p. 041403
. 41.
Alturki
, F. A.
, Abouel-Kasem
, A.
, and Ahmed
, S. M.
, 2013
, “Characteristics of Cavitation Erosion Using Image Processing Techniques
,” ASME J. Tribol.
, 135
(1
), p. 041403
. 42.
43.
Kassim
, A. A.
, Zhu
, M.
, and Mannan
, M. A.
, 2002
, “Texture Analysis Using Fractals for Tool Wear. Monitoring
,” Proceedings International Conference on Image Processing
, Rochester, NY
, Sept. 22–25
, IEEE, pp. III-105
–III-108
.44.
Yuan
, C. Q.
, Li
, J.
, Yan
, X. P.
, and Peng
, Z.
, 2003
, “The Use of the Fractal Description to Characterize Engineering Surfaces and Wear Particles
,” Wear
, 255
(1–6
), pp. 315
–326
. 45.
Stachowiak
, G. W.
, and Podsiadlo
, P.
, 2001
, “Characterization and Classification of Wear Particles and Surfaces
,” Wear
, 249
(3–4
), pp. 194
–200
. 46.
Podsiadlo
, P.
, and Stachowiak
, G. W.
, 2000
, “Scale-Invariant Analysis of Wear Particle Morphology—A Preliminary Study
,” Trib. Int.
, 33
(3–4
), pp. 289
–295
. 47.
Stachowiak
, G. W.
, 1998
, “Numerical Characterization of Wear Particles Morphology and Angularity of Particles and Surfaces
,” Trib. Int.
, 31
(1–3
), pp. 139
–157
. 48.
Ghosh
, K.
, and Pandey
, R. K.
, 2020
, “Fractal Assessment of Thin Films Deposited by Random and Ballistic Deposition Models
,” Proceedings of the AIP Conference
, 2265
, p. 030316
. 49.
Russ
, J. C.
, 2001
, “Fractal Analysis,” Encyclopedia of Material: Science of Technology
, pp. 3247
–3254
. 50.
Zhang
, J.
, 2006
, “Detection and Monitoring of Wear Using Imaging Methods
,” Ph.D. thesis
, Univ. of Twente
, The Netherlands
.51.
Babadagli
, T.
, and Develi
, K.
, 2000
, “Fractal Analysis of Natural and Synthetic Fracture Surfaces of Geothermal Reservoir Rocks
,” 2000 World Geothermal Congress
, Kyushu-Tohoku, Japan
, May 28–June 10
, pp. 2515
–2520
.52.
Lewis
, A. S.
, and Knowles
, G.
, 1992
, “Image Compression Using the 2-D Wavelet Transform, Image Processing
,” IEEE Trans.
, 1
(2
), pp. 244
–250
.53.
Huang
, K.
, and Aviyente
, S.
, 2008
, “Wavelet Feature Selection for Image Classification
,” IEEE Trans. Image Process
, 17
(9
), pp. 1709
–1720
. 54.
Mallat
, S. A.
, 1999
, Wavelet Tour of Signal Processing
, Academic Press
, New York
.55.
Bohler
, U.
, 2000
, Special Steel Manual, A-8605 Kapfenberg
, Germany
, 90
–98
.56.
Vander
, V.
, and George
, F.
, 1984
, Metallography Principles and Practices
, McGraw-Hill
, New York
.57.
Abouel-Kasem
, A.
, Abd-Elrhman
, Y. M.
, Ahmed
, S. M.
, and Emara
, K. M.
, 2010
, “Design and Performance of Slurry Erosion Tester
,” ASME J. Tribol.
, 132
(2
), p. 021601
. 58.
Saleh
, B.
, and Ahmed
, S. M.
, 2013
, “Slurry Erosion–Corrosion of Carburized AISI 5117 Steel
,” Tribol. Lett.
, 51
(1
), pp. 135
–142
. 59.
Abdelaal
, O.
, Heshmat
, M.
, and Abdelrhman
, Y.
, 2020
, “Experimental Investigation on the Effect of Water-Silica Slurry Impacts on 3D-Printed Polylactic Acid
,” Tribol. Int.
, 151
, p. 106410
. Copyright © 2022 by ASME
You do not currently have access to this content.
