Introduction , Procedure & Literature Review

1. INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
Study on Slurry Erosion of Different
Heat Treated Steel
Presented By
Presented By
Mitul Rawat
12216013
A DISSERTATION
Supervised By
Dr. Sourav Das
MMED,IITR
Dr. Subhankar Dasbakshi
Products Division,Tata Steel

2. Outline.
1. Research Aim
2. Literature Review
3. Plan of Work
4. Result and Discussion
5. Conclusion
6. Scope for Future work

3. Research Aim.
• Research aim is to focus on study of slurry erosion on different
heat-treated steel.
• Applications of this particular alloy steel includes in
earthmoving, mining, and ore processing which are subjected to
high erosion.
• Review and testing of wear behaviour for varying hardness and
phase.

4. Literature Review.
Need for a wear resistant alloy.By heat treatment erosion can be reduced if
ductility can be maintained when increasing hardness.
Justification of Problem
Erosive Wear depends on
❖ Angle of impingement
❖ Particle rotation at impingement.
❖ Particle velocity at impingement.
❖ Particle size.
❖ Surface properties.
❖ Shape of the surface.
❖ Stress level in the surface.
❖ Particle shape and strength.
❖ Particle concentration in the fluid stream.
❖ Nature of the carrier gas and its temperature

5. Literature Review.
Justification of Problem
• Pitting & Indentation on soft wear surface(Dasgupta 1999)
• Only 50-90% of K.E. of erosion particles used. (Clark 1993)
• Wear Involves both erosion & corrosion(Chakraborty 1991)
• Ploughing is favourable in low slurry concentration low speeds (Rambabu
2009)
• Large grit size leads to higher erosion. (Knuuttila 1999)
Effect of Microstructure on Erosion Mechanisms
❖ Lips Formation
❖ Ploughing
❖ Crater Formation
❖ Platelet Mechanisms
❖ Secondary Wear

6. Plan of Work.
Stage-1
Materials
Stage-2
Processing
Stage-3
Apparatus
Setup
Stage-6
Deformations
Study
Stage-5
Surface
Analysis
Stage-4
Wear Testing
Stage-7
Hardness
Tests
Conclusion

7. Results and DiscussionsTemperature
Time
A 3
A 1
930℃
WQ
Air Cooled
Slow Cooling
Heat Treatment of Low Carbon Steel Samples

8. Results and Discussion
Normalised Waterquenched Annealed
Element C Mn S Si P Al Ti Cr N
Conc(%) 0.1469 0.86 0.008 0.015 0.024 0.058 0.012 0.025` 55ppm

9. Microstructures - Annealed
After Erosion Before Erosion

10. Microstructures - Normalised
After Erosion Before Erosion

11. Microstructures - Waterquenched
After Erosion Before Erosion

12. Results and Discussion.
Weared Surface of Samples Polished Surface of Samples

13. Results and Discussion.
Heat Treatment
Sample Treatment Hardness Temperature/Cooling
Time
Sample 1 Water Quenched 508 VHN 930°C / 1hr water cooled
Sample 2 Annealed 155 VHN 930°C
Sample 3 Normalized 203 VHN 930°C / 4hrs air cooled

14. Results and Discussion.
Heat Treatment
Sample Treatment Hardness Temperature/Cooling
Time
Sample 1 Water Quenched 508 VHN 930°C / 1hr water cooled
Sample 2 Annealed 155 VHN 930°C
Sample 3 Normalized 203 VHN 930°C / 4hrs air cooled

15. Results and Discussion.
Weight Loss Observations
Duration (in
hr)
Weight Loss (in mg)
Annealed(±0.56) Normalized(±0.41) Water Quenched(±0.56)
0 0.00 0.00 0.00
1 26.72 12.90 4.59
2 29.69 18.84 9.27
3 36.83 26.54 12.39
4 43.55 31.91 20.70
5 49.43 34.16 20.16
6 49.82 38.63 9.99
7 53.27 41.21 26.18
8 59.39 44.57 27.86
9 63.29 50.99 24.45
10 65.15 56.03 27.62
11 68.27 59.36 30.11
12 94.00 64.97 34.91
Sample Annealed Normalized Water Quenched
Slope(mg/hr) 4.95 4.45 2.66
Hardness 155 VHN 243 VHN 508 VHN

16. Results and Discussion.
Weight Loss Observations
Duration (in
hr)
Weight Loss (in mg)
Annealed(±0.56) Normalized(±0.41) Water Quenched(±0.56)
0 0.00 0.00 0.00
1 5.70 7.59 6.36
2 7.83 7.05 6.12
3 9.81 8.88 7.50
4 11.91 10.47 9.18
5 12.75 11.22 9.42
6 14.34 12.42 11.04
7 15.30 13.77 11.76
8 16.56 14.13 12.42
9 19.83 14.19 14.61
10 20.70 16.56 14.82
Sample Annealed Normalized Water Quenched
Slope(mg/hr) 4.95 4.45 2.66
Hardness 155 VHN 243 VHN 508 VHN

17. Result and Discussion.
Hardness Measurements
S. No.
Hardness(VHN)
Water Quenched(±17) Normalized(±5) Annealed(±3)
Before
Erosion
After
Erosion
Before
Erosion
After
Erosion
Before
Erosion
After
Erosion
1 514 896 243 300 160 238
2 494 894 254 304 156 238
3 454 882 227 306 157 228
4 487 933 243 305 155 233
5 594 910 249 310 150 227
Mean 508 903 243 305 155 233

18. Hardness Measurements

19. Result and Discussion.
Surface Roughness
Points
Before Erosion After Erosion
Ra(m)
Rz(m)
Rq(m)
Ra(m)
Rz(m)
Rq(m)
1 0.04 0.5 0.05 0.43 4.5 0.79
2 0.04 0.4 0.05 0.49 6.8 1.07
3 0.11 1.5 0.19 0.22 2.6 0.32
4 0.06 0.6 0.09 0.62 6.4 1.02
5 0.05 0.5 0.07 1.07 8.3 1.68
Mean
0.06 0.7 0.09 0.57 5.72 0.98
Points
Before Erosion After Erosion
Ra(m)
Rz(m)
Rq(m)
Ra(m)
Rz(m)
Rq(m)
1 0.07 1 0.11 0.12 1.3 0.17
2 0.06 0.9 0.1 0.08 0.8 0.11
3 0.06 0.5 0.07 0.1 1.2 0.15
4 0.05 0.5 0.07 0.08 0.8 0.11
5 0.06 0.5 0.07 0.11 1.4 0.16
Mean
0.06 0.68 0.08 0.098 1.1 0.14
Points
Before Erosion After Erosion
Ra(m)
Rz(m)
Rq(m)
Ra(m)
Rz(m)
Rq(m)
1 0.04 0.5 0.05 0.12 1.3 0.17
2 0.05 0.4 0.04 0.08 0.8 0.11
3 0.04 0.4 0.005 0.1 1.2 0.15
4 0.06 0.6 0.09 0.08 0.8 0.11
5 0.05 0.5 0.07 0.11 1.4 0.16
Mean 0.05 0.48 0.05 0.1 1.1 0.14
Waterquenched Sample Normalised Sample
Annealed Sample

20. Surface Roughness Measurements

21. Result and Discussion.
Surface FESEM Images
Annealed SampleWater Quenched SampleNormalized Sample

22. Result and Discussion.
● Water quenched sample has least intensity peaks signifying minimum deformation.
● Peaks of Annealed sample are widest due to maximum deformation and wear.
Normalized sample has medium deformation and hence medium width of peaks.

23. Result and Discussion.
Embedded Particle in
Annealed Steel
Embedded Particle in Water
Quenched Steel

24. Result and Discussion.
Crater Formation in Water
Quenched Sample
Cracks propagation in Normalized
Lips formation followed by
chipping in Annealed Sample
Crater Formation in Water Quenched

25. Result and Discussion.
Ploughing followed by cracking in
Normalized Sample
Ploughing in Annealed Sample

26. Result and Discussion.
Craters due to concentrated impact of particles at
one position in Water Quenched Sample
Secondary Wear - Chipping of Material in
Water Quenched Sample

27. CONCLUSION.
● Erosion in ductile metals occurs via ploughing, lips formation ,cracks, ridges and
chipping.
● The harder the surface is lower will be the wear rate. Along with wear,
phenomenon of
● embedding of particles into the matrix is observed in martensite sample due to high
hardness.
● Diffraction peaks depict the extent of deformation in material.Wider the diffraction
peaks, more is deformation.
● Water quenched being hardest among the three sample suffered least erosion.
● Comparison of wear rates and hardness further justifies the inverse relation
between hardness and erosion

28. Scope of Future Work.
● Study of solid particle erosion using advanced morphological apparatus.This
will benefit in understanding the fracture mechanisms and impact of sand
particles at nano levels.
● Strain hardening occurring during testing can be studied using advanced
setups.This will benefit in understanding effect of tensile stress on erosion.
● Revised Heat Treatment Process taking into account current conclusions.