ACTA UNIVERSITATIS AGRICULTURAE ET SILVICULTURAE MENDELIANAE BRUNENSIS

Volume LIX 2 Number 3, 2011

ABRASIVE AND EROSIVE WEAR

OF TECHNICAL MATERIALS

P. Doubek, J. Filípek

Received: February 4, 2011

Abstract

DOUBEK, P., FILÍPEK, J.: Abrasive and erosive wear of technical materials. Acta univ. agric. et silvic. Mendel.
Brun., 2011, LIX, No. 3, pp. 13–22

Operating reliability of agricultural, transport and construction machines is in a considerable

degree influenced by corrosion and wear. These sorts of damage significantly influence the costs
for the restoration of mechanical components, as well as their service and repairs. This article deals
with comparing the abrasive and erosive wear of technical materials (so steel, wear-resisting steel,
ledeburitic cast-iron, cemented carbides). A test of the abrasive wear by means of bound particles was
carried out on an apparatus with a corundum abrasive cloth. The erosive wear was made in a testing
mechanism manufactured by the firm Kovo Staněk Ltd., which simulated the operating conditions by
jetting with both spheroidal granulate and angular crushed material.
The comparative resistance against the abrasive wear of the tested materials varied by three degrees.
The testing conditions and the working means affected not only the wear formulated in absoulute units
(g, mm3), but also the proportional resistance against the wear, which could be changed by a degree.
According to these results, appropriate materials for the inside lining of the working chambre and for
the casting wheel paddles of the jetting appliance could be found.

abrasive wear, erosive wear, laboratory test, operating test, abrasive cloth, jetting mechanism

The inherent machine reliability is given by its operating reliability is also formed by the way
structural solving, by its way of manufacturing of working use and by the system of machine
and by observing the technological discipline maintenance (Fig. 1).
in production (Legát et al.). The level of machine

1: General time process of the machine reliability level

13
14 P. Doubek, J. Filípek

The chosen construction material and its wear of ploughshares (Votava et al., 2007). The other
resistence against the abrasive and erosive wear can occurence shows a wear by the particles placed
significantly cause the inherent machine reliability. between two functional surfaces. This situation
In agriculture, enormous wear of machine works means an interaction of three bodies. In practice,
occurs especially in soil cultivation. A very good this configuration can be met in various movable
example of wear mentioned above is abrasive impositions (Fig. 2 b), at crushing minerals, etc.
wear of ploughshares. The issue to be taken into In order to extend the period of using those
consideration is the way of heat treatment, which machine parts operating in conditions of possible
makes a compromise between hardness and abrasion, different abrasion-resisting materials can
persistence. Carbon closed in iron grid  causes be used, as e. g. wrought abrasion-resisting steel
high internal stress within the material, which (XAR, Brinar, Dillidur, Durostat, Domex Wear,
rather results to high hardness, but to a big loss of Fora, HARDOX, etc.), casting steel (Hadfield steel,
toughness, and thus to a higher risk of cleavage chromium carbide steel), alloyed white cast iron,
fracture and subsequent fragmentation of cemented carbide, technical ceramics, overlays
ploughshares (Votava et al., 2005). (martensitic, austenitic, ledeburitic) etc. Hardened
The abrasive wear is described as the separating of carbon steel with normal quality 11 700 (E360)
material particles from the functional surface by the has got twice as much resistance than etalon steel
harder and rougher surface of another body, or by 12 014.20 (C06E) with 100 HV hardness (Suchánek et
abrasive particles (Blaškovič et al., 1990). According al., 2007).
to mutual interactions at the abrasive wear, two The erosive wear is a constantly undesirable
basic types can be differentiated. The first one shows change of the surface and dimensions caused by
a wear due to the interaction of two bodies, most the mutual action of the functional surface and
oen of the particles and the functional surface, the wearing medium. It is shown as a removing
a typical example of it is the wear of components of particles from the deteriorated surface by the
during soil cultivation (Fig. 2 a), row material mining mechanical impact, in some case accompanied
etc. In soil cultivation, the amount of soil skeleton with other influence as well, e. g. chemical,
is one of the most significant factors of abrasive electrochemical, electric. The mechanism of an

new

used
a – plough share (Filípek, ýerný, 2007) b – piston (Pošta, 2002)

2: Examples of abrasive wear

3: Erosive wear of an air-blast blade

 Abrasive and erosive wear of technical materials 15

outside wear is similar to the abrasive wear, i.e. it (hardened and low-relaxed steel, white cast-iron,
comes to rippling and trimming of the material. As hard overlays, cemented carbide, ceramics) seem
typical for this erosive wear, a non-even damaging better.
of the surface can be observed, which is waved,
corrugated and damaged even in the cavities
MATERIAL AND METHODS
(Červený, 2008). The erosive mechanisms are also
utilized in technological applications, e. g. in surface The wear was evaluated according to dimensional
finishing by jetting (Fig. 3) and cutting materials with and mass decrease of three samples during the
water jet with particles. abrasive and erosive wear at laboratory and operative
The effects of single factors on the erosive wear testing. The comparative resistance is related to the
intensity are very important, namely on the shape, etalon made from low-carbon steel.
hardness, dimension and the quantity of solid
particles, the impact velocity and angle, the hardness Probationary specimens
and the material micro-structure (Suchánek, The resistance against wear was tested on six sorts
2006). So and ductile materials (anneal steel) are of technical materials, the parameters of which can
appropriate to be used by big impact angles, on be seen in Chart I. Fig. 4 shows the micro-structure
the contrary, by small impact agles hard materials of some selected materials.

I: Characteristics of tested materials

Density Hardness
Material Characteristic Prize CZK/kg
[g.cm−3] [HV10]
Steel 11 373
Low-carbon ferritic-pearlitic steell 7.75 129 12
(S235JRG1)
Low-alloyed abrasion-resistant steel, heat-
Creusabro 4800 treated, oil-hardened (martenzitic-bainitic 7.74 412 43
structure)
Abrasion-resistant austenitic manganese
Creusabro M 7.70 280 74
steel treated by solvent annealing
Material of throwing wheel blade (abrasion-
Sedur 204 7.34 803 300
resistant alloyed white cast iron)
K10 Cemented carbide (5 % Co) 14.61 1 801 1 500
K20 Cemented carbide (6 % Co) 14.62 1 752 1 500

a – Steel 11 373 b – Creusabro 4800

c – Creusabro M d – Sedur 204

4: Microstructure of selected materials
16 P. Doubek, J. Filípek

Jetting material by a weight to the abrasive cloth. During the testing,

Two sorts of jetting material were used for an the horizontal disk with the abrasive cloth is rotated
operative test (Trimeta, 2010): and the tested body is moved from the centre to the
• AMASTEEL S 230 – round granulate (Fig. 5 a) edging of the abrasive cloth. Aer the given length
of the wearing course, the terminal switch will stop
Round and heat improved granulate from
the machine. The specimens are the cleaned and the
hypereutectoid steel with sorbitic structure,
weight decrease determined by weighing.
hardness 40–50 HRC. Size marking S 230 responds
Proportional resistance against wear  was set
to the accumulated proportion retained over
according to relations:
testing sieves, mesh size: 1.00 mm – 0 %, 0.85 mm
– max. 10 %, 0.60 mm – min. 85 %, 0,50 mm – min. met
97 %. mass − m =  (1)
mvzo
• AMASTEEL LG 40 – sharp edged crushed material
(Fig. 5 b). where:
Crushed material from hypereutectoid steel with met ....mass loss of etalon or specimen [g]
structure of the tempered martenzit, hardness 54– mvzo .. specimen weight decrease [g].
61 HRC, the edges of which are gradually rounded
by jetting. Size marking LG 40 responds to the met

accumulated proportion retained over testing et
Volume − v =  (2)
sieves, mesh size: 1.00 mm – 0 %, 0.425 mm – min. mvzo

70 %, 0.30 mm – min. 80 %).  vzo

Laboratory testing of the abrasive wear where:

The laboratory testing of the wear on abrasive et.....etalon density [g.cm−3]
cloth is based on the norm ČSN 01 5084 (Fig. 6). vzo ...specimen density [g.cm−3].
The tested sample is held in a holder and pressed

a – AMASTEEL S 230 – enlarged 2x b – AMASTEEL LG 40 – enlarged 5x

5: The used jetting material

weight
set for radial motion
tested specimen

pulling head

specimen holder

abrasive cloth
apparatus
frame

horizontal disc

a – apparatus scheme b – testing apparatus

6: Laboratory test on abrasive cloth
 Abrasive and erosive wear of technical materials 17

Conditions of the laroratory test: throwing the abrasive material, the specimens are
• form of the testing specimen: cube10 × 10 × 10 mm cleaned and the weight decrease is measured by
• specimen number of each tested material: 3 weighing.
• comparing etalon: steel 11 373 (S 235 JRG1) The proportional and weight resistence against
hardness 129 HV the erosive wear  calculated according to the
• length of the friction course 250 m equation 1 and 2.
The conditions of the operative test:
• diameter of the revolving disc: 480 mm
• jetting mechanism type TZ 4–7,5~15/11–16,
• max. sliding speed of the tested body: 0.5 m.s−1 manufacturer – Kovo Staněk Ltd., Brumovice
• specific pressure: 0.32 N.mm−2 • form of the tested specimen: prism 50 × 50 × 8 mm
• radial motion of the tested body: 3 mm.ot−1 • specimens number of each tested material: 3
• abrasive cloth: corundum, granularity 120. • comparing etalon: steel 11 373 (S 235 JRG1),
hardness 129 HV
Operative test of the erosive wear
• test period: 4 hours
The tested specimens are fixed in a set installed in • abrasive material quantity: 120 kg.min−1
the working chamber of the jetting device (Fig. 7).
• throwing wheel efficiency: 7.5 kW
The specimens are attached to the fixture by side
clamp links. There are always three specimens of • circumferential speed of the throwing wheel:
one tested material attached to the fixture. Then 55 m.s−1
the abrasive material is thrown by the throwing • diameter of the throwing wheel, used for this test:
wheel blades during the given test period, always 359 mm
broken by 30 minutes’ pause aer one hour’s jetting • number of blades on this throwing wheel: 6.
onto the attached tested materials. Aer the end of

Fixture attachement

Throwing wheel Blade Abrasive Tested Fixture

mat. specimens

a – scheme operating test b – jetting mechanism

7: Operative test

II: Dimensional wear of tested specimen [mm3]

abrasive erosive
Tested
HV 10 abrasive cloth round granulate angular crushed material
material
(250 m) (4 h) (4h)
Steel 11 373 208
129 8 474 6 128
(S235JRG1) (192–225)*
160
Creusabro 4800 412 609 1 845
(158–162)*
108
Creusabro M 280 107 321
(106–110)*
31
Sedur 204 803 22.5 52.3
(29.4–31.7)*
0.388
K 20 1 752 56.2 3.3
(0.31–0.46)*
0.34
K 10 1 801 37.8 2.6
(0.34–0.34)*
* confidence interval  = 0.05
18 P. Doubek, J. Filípek

RESULTS AND DISCUSSION be an exception, where the wear is lower than the
The average cubic decrease of tested materials is corresponding hardness of the specimen.
to be seen in Chart. II. The cubic decrease was lower The appearance of tested specimens aer the
at all tested materials and also when put in any othr operative test of erosive wear can be seen on
medium than he etalon, i.e. low-carbon steel 11 373 Fig. 8. The wear is unequal, the highest decrease
(S235JRG1). is placed next to the specimen edges, which is
The weight decrease on the abrasive cloth was most perceptible at 11 373-steel. On specimens
lowered when the hardness increased. However, the from cemented carbides K10 and K20, the round
austenitic manganese steel Creusebro M seems is to granulate broke mainly off the material particles

abrasive Amasteel S 230 – round granulate

abrasive Amasteel LG 40 – angular crushed material

8: Specimen appearance after operative test
 Abrasive and erosive wear of technical materials 19

near to the specimen edges, and therefore the wear affected by many factors (impact velocity and impact
is higher than at those ones made from alloyed white angle, size, shape, hardness and quantity of erosive
cast iron Sedur 204. As concerns angular crushed particles, carrying medium, physical-mechanical
material, the wear is placed more equally on the aspects and the micro-structure of eroded material).
specimens surface; the lowest cubic decrease can be For instance, brittle materials are more resistent by
seen at those made from cemented carbides. small impact angles, on the contrary, the shapeable
Fig. 9 presents the values of the proportional and ones by large impact angles (Houdková et al., 2003).
weight resistance against the abrasive and erosive Therefore, it is necessary to determine the resistance
wear for the tested materials, in comparison to against the erosive wear experimentally (Suchánek,
the confronting specimen (steel 11 373 = 1). The 2006).
intensity of the erosive wear is in the same time co-

2500
2357
Abrasive wear – abrasive cloth
Erosive wear – round granulate
Erosive wear – angular crushed material
2000
1857

1500
I

1000

608
536
500 376

224
117 150
79
1 1 1 1.3 14 3.3 1.9 19 6.7
0
Steel
OCEL1111373
373 CREUSABRO 4800 CREUSABRO M SEDUR 204 K20 K10

a – cubic

1400
Abrasive wear – abrasive cloth 1250
Erosive wear – round granulate
1200 Erosive wear – angular crushed material

984
1000

800
I

600

398
400 323
284

200 124 119

79 80
1 1 1 1.3 14 3.3 1.9 19 6.4
0
Steel 11 373
OCEL 373 CREUSABRO 4800 CREUSABRO M SEDUR 204 K20 K10

b – weight

9: Proportional resistance against abrasive and erosive wear

20 P. Doubek, J. Filípek

SUMMARY
The wear is one of the most frequent causes that restrict the reliability and operating durability of
machines and sets. This is influenced by many factors which can be tested both singly and in their
mutual context. According to the laboratory as well as operative tests, the authors have reached
following conclusions:
• to formulate the material resistence against wear in absolute units (mm3, g) is not very clear
and depends on test conditions. It seems more opportune to determine the relative resistance
considering the selected etalon. In case of the different consistency of tested materials, it appears to
be useful to set not only the cubic resistence, but the weight relative one as well;
• the relative resistance against the erosive wear by sharp-angular crushed material was in cemented
carbides (K10, K20) higher by three periods than in low-carbon steel, while the hardness is higher
by one period only. Even if the price of cemented carbides is relatively high, their cautious use
seems preferable, as the operating life of the machinery can substantially increase;
• if austenitic manganese steel (Creusabro M) is used, according to supposition, a favourable affect
of the surface impact stress on the wear resistence is shown. In case of jetting with round granulate
it makes  = 80; however, the resistence is much lower on the abrasive cloth and in sharp-angular
crushed material;
• alloyed and abrasion-resistant white cast iron (Sedur 204) surprised by its high resistance against
the wear through the round granulate ( = 330). In this surrounding it showed a higher resistance
than cemented carbides, even if its hardness is half as high;
• low alloyed, heat treated and abrasion-resistant steel (Creusabro 4800) did not stand out by its
resistance against wear. The structure modifications by special techniques of heat treatment did not
distinctly increased the abrasion resistance. This steel was working better in operating tests than in
the laboratory testing;
• the resistance against the abrasive wear on the abrasive cloth is adequate to the recorded hardness
(Pearson corelation coefficient r = 0.89), even if the structure of the tested materials is very different.
In case of the erosive wear, the impermeability is minor to the measured hardness (r = 0.52 – round
granulate, r = 0.61 – sharp-angle crushed material);
• there is a very tight corelation (r = 0.97) between the extent of erosive wear by round granulate and
by sharp-angle crushed material;
• the results from the operative test in sharp-angled abrasive material correspond better with the
results of abrasive wear on abrasive cloth, as the hard particles are similar in their features.
The erosive mechanisms are used in treating the surface through jetting (Suchánek, 2006); however,
an erosive effect on the jetting set itself is undesirable. On the basis of laboratory and operative test
results it can be observed that the most suitable material for the inside casing of the jetting chambre
seems to be Creusabro M, which is an abrasion-resisting austenitic non-manganese steel. The
increase of resistance against wear is attached to the transformation of the metastable austenite on the
martenzite during the jetting.
As long as our choice of material for the throwing-wheel blades would be based on the results from
the test ČSN 01 5054 (Czech Norm) only, i. e. from the resistance on abrasive cloth, so it can be said
that definitely the most resistant materials seem to be the cemented carbides K10 and K20. However,
in an operative test with the round granulate, it was the white abrasion-resistant cast iron Sedur 204
that is the best material resisting the erosive wear. When compared with cemented carbides, it is more
resisting, cheaper and it has the half density. In case of using the sharp-angle crushed material, Sedur
204 as well as the cemented carbide K20 can be recommended for the throwing-wheel blades.

Acknowledgment
This paper was written with co-operation with the firm Kovo Staněk, Ltd., Brumovice 412, 691 11.

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Address
Ing. et Ing. Petr Doubek, doc. Ing. Josef Filípek, CSc., Ústav techniky a automobilové dopravy, Mendelova
univerzita v Brně, Zemědělská 1, 613 00 Brno, Česká republika, [email protected], fi[email protected]
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