Experiment and simulation study on cavitation flow in pressure relief valve at different hydraulic oil temperatures

Hydraulic oil is the “blood” of hydraulic system, its high temperature in low-pressure hydraulic system would promote the development of cavitation and cause severe erosion of pressure relief valve. The influence of high oil temperature on the distribution of pressure field, velocity field and vapor volume fraction are discussed experimentally and numerically. The results show that with the increasing oil temperature, the viscosity of the oil decreases, and the flow rate increases, resulting the decreasing pressure at the orifice. Higher oil temperature promotes the occurrence of cavitation in the pressure relief valve, wider low-pressure zone could be found and cavitation bubble developed more fully and towards the valve core head. When the oil temperature increases from 303 K to 353 K, the cavitation intensity rises more sharply, but the growth rate of cavitation intensity increases firstly and then decreases with the increasing input pressure. Furthermore, based on the field synergy theory, the flow resistance and energy dissipation under different oil temperatures are evaluated. Both of large viscous dissipation and effective viscosity coefficient are mainly concentrated at the orifice, which are all effected by the oil temperature, so as to the characteristics of cavitation flow. The average field synergy cosine angle and the average viscosity coefficient decreases gradually with the increasing oil temperature, while the average vapor volume fraction increases. The energy dissipation is reduced by 3.3 × 10⁷ (W m⁻³) while the hydraulic oil temperature increases from 303 K to 353 K. Appropriate hydraulic oil temperature could provide favourable working conditions for the pressure relief valve which is beneficial for extending the hydraulic system's service life.     

Cavitation damage incubation with typical fluids applied to a scroll expander system

During the operation of a scroll expander system overpressure may occur resulting in cavitation damage. Impacts due to implosion of cavitation bubbles near to suction ports can result in damage to the scroll plate in the expander. The accumulation of cavitation pits across the scroll plate leads to cavitation erosion hence efficiency drop. An experimental analysis to identify the mechanical damage of the cavitation on various steel surfaces with different liquid environments was conducted.Three liquid environments and four steel grades were utilised experimentally. The liquids used for the tests were distilled water, used as a reference liquid, and the two working fluids of the scroll expander a synthetic lubricant and a high molecular refrigerant. The steel grades were a high carbon (AISI 1085) and low carbon (AISI 1010) martensitic steel with retained austenite, a chromium martensitic steel (AISI 52100) and a martensitic scroll plate (SP) sample. An ultrasonic transducer was utilised to produce cavitation conditions using a 5 mm diameter probe. The comparison of the results revealed the most hostile liquid environment according to the morphology evaluation of the incubation pits. The cavitation mechanisms are discussed and the cavitation resistance of the steel grades is evaluated. The best performing steel material against cavitation is determined for the conditions described.     

Cavitation damage incubation with typical fluids applied to a scroll expander system

During the operation of a scroll expander system overpressure may occur resulting in cavitation damage. Impacts due to implosion of cavitation bubbles near to suction ports can result in damage to the scroll plate in the expander. The accumulation of cavitation pits across the scroll plate leads to cavitation erosion hence efficiency drop. An experimental analysis to identify the mechanical damage of the cavitation on various steel surfaces with different liquid environments was conducted.Three liquid environments and four steel grades were utilised experimentally. The liquids used for the tests were distilled water, used as a reference liquid, and the two working fluids of the scroll expander a synthetic lubricant and a high molecular refrigerant. The steel grades were a high carbon (AISI 1085) and low carbon (AISI 1010) martensitic steel with retained austenite, a chromium martensitic steel (AISI 52100) and a martensitic scroll plate (SP) sample. An ultrasonic transducer was utilised to produce cavitation conditions using a 5 mm diameter probe. The comparison of the results revealed the most hostile liquid environment according to the morphology evaluation of the incubation pits. The cavitation mechanisms are discussed and the cavitation resistance of the steel grades is evaluated. The best performing steel material against cavitation is determined for the conditions described.     

低层错能FeMnSiCrCu形状记忆合金的空蚀

对低层措能Fe—26Mn—6Si—7Cr—lCu形状记忆合金和0Crl3Ni5Mo不锈钢进行了空蚀试验。结果表明，Fe—26Mn—6Si—7Cr—lCu形状记忆合金杭空蚀性能优于0Crl3Ni5Mo不锈钢。空蚀过程中应变诱发马氏体转变是该形状记忆合金具有良好杭空蚀性能的主要原因。     

Cavitation and high-velocity slurry erosion resistance of welded Stellite 6 alloy

The cavitation and slurry erosion resistances of Stellite 6 coatings and 13-4 stainless steel were compared in laboratory. The Cavitation Resistance (CR) was measured according to ASTM G32 standard and the Slurry Erosion Resistance (SER) was tested in a high-velocity erosion tester under several impact angles. The results showed that the coatings improved the CR 15 times when compared to bare stainless steel. The SER of the coatings was also higher for all the impingement angles tested, the highest erosion rate being observed at 45°. The main wear mechanisms were micro-cracking (cavitation tests), and micro-cutting and micro-ploughing (slurry erosion tests).     

Oxidation Stability and Tribological Behavior of Vegetable Oil Hydraulic Fluids

The new generation of vegetable oil hydraulic fluids has a price advantage and provides field longevity comparable to synthetic esters at moderate temperature.

This article investigates the oxidation stability and tribological behavior of fully formulated vegetable oil hydraulic fluids. Differences in origin (canola, soybean, and sunflower oil) and the degree of unsaturation are studied. Modified ASTM D943 (Dry TOST) was found reliable to evaluate the impact on oxidative stability of various additive packages in vegetable oils. Tribological testing utilized laboratory hydraulic pumps such as the Vickers V 104C, Vickers 20VQ, and Vickers PFB-5 under a variety of temperatures, pressures, pump outputs, and speeds. The conditions of aging fluids were monitored by evaluation of TAN, viscosity, wear rate, and depletion of antioxidants. Voltammetric technique was applied to determine the concentration of antioxidant in systems. Based on analysis of antioxidant consumption, the main degenerative process in vegetable oils under demanding pump operations is similar to pyrolytic degradation, rather than oxidation.

By selecting the appropriate synergistic additive packages, a remarkable pump longevity can be obtained for each vegetable base stock studied.     

Erosion of metals using angular silicon carbide particles

ABSTRACT

In this work, erosion tests conducted to evaluate the resistance of two materials, Metal Babbitt Grade 7 and AISI T1 against SiC particles. The erosion rates of these two metals compared with those obtained using AISI D2 steel in a previous work with similar testing conditions. Metal Babbitt and AISI T1 steel selected due to their high ductility and strength, respectively. A test rig similar to that shown in ASTM G76-95 standard used to perform the tests. Silicon carbide particles had a particle size between 350–450 µm. Tests carried out using different impact angles, 30°, 45°, 60° and 90° with a particle velocity of 24 ± 2 m/s and the abrasive flow rate was 0.7 ± 0.5 g/min. SEM photographs used to identify the wear mechanisms on the Babbitt and T1 steel and also obtained cross-section images of the wear scars on metal Babbitt to measure their depth.     

Failure analysis of melt urea pump impeller

Abstract

A melt urea pump is out of work after only 6 days in service. The failure of the melt urea pump impeller is analysed using different methods including chemical composition analysis, metallographic observation, SEM and energy dispersive spectroscopy analyses, etc. The results show that the material of the impeller is not the reported AISI 321 stainless steel but AISI 316 stainless steel. There are many honeycombed holes on its impeller, which is the typical feature of cavitation damage. Therefore, the main failure reason of the impeller is the cavitation erosion, and the electrochemical corrosion of the medium also accelerated the failure of the impeller. The failure of the impeller is not related with the as casted defects of the material because no obvious as casted defects are found in the material.     

Surface integrity and part accuracy in reaming and tapping stainless steel with new vegetable based cutting oils

This paper presents an investigation on the effect of new formulations of vegetable oils on surface integrity and part accuracy in reaming and tapping operations with AISI 316L stainless steel. Surface integrity was assessed with measurements of roughness, microhardness, and using metallographic techniques, while part accuracy was measured on a coordinate measuring machine. A widely diffused commercial mineral oil was used as reference for all measurements. Cutting fluid was found to have a significant effect on surface integrity and thickness of the strain hardened layer in the sub-surface, as well as part accuracy. Cutting fluids based on vegetable oils showed comparable or better performance than mineral oils.     

Experimental Study on Influences of Surface Materials on Cavitation Flow Around Hydrofoils

In order to resist on the cavitation erosion, many researchers try to change the solidity and tenacity of the coatings,but ignore the influence of surface characteristics of materials on cavitation flow and the interaction with each other.In this paper, high speed visualization system is used to observe the cavitation flow patterns in di erent stage. After comparing the characteristics of cavitation flow around hydrofoils made of aluminum(Foil A), stainless steel(Foil B)and the hydrofoil painted with epoxy coating(Foil C), the study shows that material has a significant e ect on the cavitation flow. Firstly, when the incipient cavitation occurs, cavitation number of Foil A is highest among three hydrofoils, generating horseshoe vortex randomly. For Foil B and Foil C, it shows in the form of free bubbles. When the sheet cavitation occurs, Foil A has the highest cavitation number and shortest period, which is contrary to Foil C. And cavity consists of lots of small finger-like cavities. For Foil B and Foil C, it both constitutes with many bubbles. Compared with the high-density and small-scale cavities over surface of Foil C, the cavity of Foil B has larger scale and less density,which causes a minimal scope of influence of the re-entrant jet and strong randomness. When the cloud cavitation occurs, Foil C has the lowest cavitation number and shortest period. Secondly, compared with aluminum, both of stainless steel and epoxy coating restrains the occurrence and development of cavitation, and stainless steel and epoxy coating performs better than aluminum. For inception and sheet cavitation, stainless steel performs better than epoxy coating and aluminum. For cloud cavitation, epoxy coating performs better than stainless steel and aluminum.The objective of this paper is applied experimental method to investigate the e ect of surface materials on cavitation around Clark-Y hydrofoils.     

Effect of the stress level on the cavitation erosion rate

The effect of stress on the cavitation erosion rates of cast iron and mild steel was studied using a specially developed ultrasonic test rig. The mechanism of erosion experienced in the test rig is discussed.     

Erosion–corrosion assessment of materials for use in the resources industry

The erosion–corrosion properties of a range of ferrous-based materials that are currently being used or have potential for use in the resources industry have been assessed using a slurry pot erosion–corrosion (SPEC) test rig that has the capability of establishing the separate components of erosion, corrosion and synergy.Testing was performed, at 30 °C, in an aqueous slurry containing 35 wt% AFS 50–70 silica sand and a 3.5 wt% NaCl solution. Erosive action was supplied through high-speed rotation of a rubber-lined impeller.Erosion–corrosion performance of materials evaluated was related to composition/microstructure and hardness. Test data correlated with available service experience.The results showed that the cast Cr white irons with (i) a structure that was essentially a duplex stainless steel containing a distribution of hard carbides and (ii) a near eutectic Cr white iron exhibited the highest erosion–corrosion resistance of the materials tested. The evaluation of the Cr white irons also highlighted the influence of Cr and C levels on the E–C properties of these materials.E–C assessment of selected carbon steels confirmed that the erosion-only rates and synergistic levels showed a general decline with increasing carbon content and hardness. As expected, a low C steel pipe product displayed very mediocre erosion–corrosion behaviour as a consequence of its very low intrinsic corrosion resistance and inferior wear properties. This reflected service experience, however, such products are still being used, due to the comparatively low initial cost.A TiC particle-reinforced AISI 316 stainless steel exhibited an almost 45% improvement in the E–C resistance, when compared with an AISI 316L stainless steel.     

An experimental study on cavitation erosion-corrosion performance of ANSI 1020 and ANSI 4135 steel

Cavitation erosion is quite complex, containing corrosion-erosion interaction effect. High temperature oxidization may be aroused after bubble collapse, accompanied by hot gas contacting with the pump component surface. The analysis of the erosion pits can be an effective way to know the mechanism of cavitation erosion. In present paper, the cavitation erosion resistance of carbon steel (ANSI 1020) and alloy steel (ANSI 4135) were tested in an ultrasonic vibration apparatus. By using energy dispersive X-ray spectroscope and three dimensional laser microscope, the chemical composition around erosion pits and the oxidation film structure were analyzed. By using metallographic microscope and scanning electronic microscope, the metallographic structure of specimens (e.g., carbon steel and alloy steel), the nano structured iron oxide and corresponding influence on specimen’s anti-erosion performance were discussed. Based on the comparison between the different tests performed in distilled water and tap water respectively, results can be obtained that erosion rate of carbon steel and alloy steel varies with the component of water which had close correlation to the oxidation effect. Erosion rate of alloy steel 4135 was much lower in distilled water compared to tap water while the difference of carbon steel 1020 was not that large. The remarkable different responses of these two materials had close relationship with oxidation effect. The oxidation effect transferred the original structure of alloy steel surface which had high anti-erosion capability, into newly generated iron oxide structure, which was preferentially to be attacked. The pumping of slightly corrosive fluids frequently leads to erosion-corrosion damage on impellers, and corrosion can further amplify the erosion process.     

铸铁气蚀破坏机制

从铸铁基体组织，石墨形态，合金元素等方面探讨铸铁气蚀性能的影响因素，分析空化的力学冲击作用与气蚀时的材料受力情况，研究铸铁气蚀裂纹核的形成与扩展乃至导致铸铁气蚀破坏的过程，剖析球墨铸铁的气蚀特点。     

A review of the performance of engineering materials under prevalent tribological and wear situations in South African industries

The wear of materials used on machinery operating in a wide range of industrial situations such as mining, energy production and agriculture can cause serious inefficiencies, sudden breakdowns and consequential financial losses. Our work over two decades has concerned industrial problems encountered in South African industry, and laboratory simulations of abrasion, abrasion plus corrosion, adhesive wear, impact wear, cavitation, solid particle erosion and erosion plus corrosion situations have been successfully undertaken. Materials investigated include plain carbon and alloy steel, stainless steels, aluminium alloys, cast irons, tungsten carbide cermets, ceramics, polymers, composites and various surface treated and coated materials. The paper reviews the investigations carried out in our laboratories and conclusions we have made.     

Improving the wear life of a cocoa spray‐drying unit

In the chocolate production process, the moisture content of ground cocoa is removed in a spray‐drying unit, in which wet cocoa is pumped through a high‐pressure pump. Wear occurs in this high‐pressure pump, which can cause problems in the system. Originally, valves and beds were made of AISI 316 Ti austenitic stainless steel, and their average wear life was less than 280 h, obviously too short for use in industrial production. The aim of the research reported in this paper was to investigate ways to increase the wear life of these parts. In this respect six different materials were tested. Valves and beds were produced from four different steels and two powder metals. The steel parts were hardened by heat treatment. All the parts were electroplated with CrN or TiN. Wear life tests were carried out, and it was shown that AISI M2 high‐speed steel valves and beds gave the longest wear lives.     

Characterization of Erosion of Metallic Materials Under Cavitation Attack in a Mineral Oil

Cavitation erosion and erosion rates of eight metallic materials representing three crystal structures were studied. The erosion experiments were conducted with a 20-kHz ultrasonic electrostrictive oscillator in a viscous mineral oil. The erosion rates of the metals and alloys varied over three orders of magnitude. The erosion rates of brittle metals, iron, and molybdenum were higher than that of the titanium alloy but lower than the rest of the soft ductile metals and alloys. Studies with scanning electron microscopy indicated that the cavitation pits were initially formed at the grain boundaries and precipitates and that the pits formed at the junction of grain boundaries grew faster than the others. Transcrystalline craters formed by cavitation attack over the surface of grains and roughened the surfaces by multiple slip and twinning. Surface roughness measurements showed that the pits formed over the grain boundaries deepened faster than other pits. Computer analysis revealed that a geometric expression describes the normalized erosion curves during the time period 0.5 t₀ < t < 2.5 t₀, where t₀ is the incubation period. The fcc metals had very short incubation periods; the titanium alloy had the longest incubation period.     

A study on erosive wear behavior of HVOF sprayed nanostructured WC-CoCr coatings

WC-CoCr cermet coatings were deposited on stainless steel substrate using high-velocity oxy-fuel (HVOF) thermal spray process. The coatings were developed with two different thermal spray powders: one has WC grains of conventional micron size and the other is composed of nanosized (near-nanostructured) grains. HVOF spraying was assisted with in-flight particle temperature and velocity measurement system to control the process parameters that have resulted in quality coatings. Cavitation erosion testing was performed using a vibratory test apparatus based on ASTM standard G32-98. Surface morphology of powders and coatings was examined using the FESEM images, and phase identification was performed by XRD analysis. The erosion behavior of coatings and mechanism of material removal was discussed by examining the microstructure images of worn-out surfaces. WC-CoCr cermet coating deposited with nanosized WC grains exhibited higher cavitation erosion resistance as compared to conventional coating.     

Cavitation Erosion and Sliding Wear to Assess Carbide Integrity in AISI D2 Tool Steel

Ultrasonic cavitation and ball-on-disk wear tests were conducted in order to assess the carbide integrity in AISI D2 steel specimens with different heat treatments and carbide orientations on the exposed surface. The response of the tested materials under cavitation erosion was clearly distinguishable for each carbide orientation and heat treatment. Particularly, carbide predominant orientation can be successfully associated with the incubation period of cavitation damage. Validity of the cavitation erosion tests as a useful characterization technique in materials with reinforcement phases is discussed based on the small contact areas associated with the microjets generated in the ultrasonic cavitation test. On the other hand, ball-on-disk tests in conjunction with conventional wear analysis (coefficient of friction graph, wear volume) did not provide a clear relationship between research variables. However, by using discrete Fourier analysis from friction coefficient data, it was possible to establish a correlation between integrity of primary carbide, its orientation and matrix hardness.     

Metalworking fluids from vegetable oils

The biodegradability of metalworking fluids has assumed very high priority. Biodegradable metalworking fluid formulations consist of vegetable oil, an emulsifier, co‐surfactant, fungicide and additives. Non‐edible vegetable oils such as neem, ricebran, and karanja oil are renewable, biodegradable and cheaper than synthetic fluids. Oleates and fatty‐acid amides of these oils have been used as emulsifiers to eliminate biohard emulsifiers. Additives are used to achieve a high level of performance. Metalworking soluble oil formulations were evaluated for physico‐chemical characteristics such as emulsion and thermal stability, copper‐strip corrosion, iron chip corrosion, deposit‐forming tendency on hot metal surfaces, and lubricity. Oil–water micro‐emulsions of these oils have higher stability. The emulsions were stable over a wide range of temperatures. Performance of formulations from all three oils are found at par with the ASTM specifications. Neem oil based formulation showed better characteristics than ricebran and karanja oil. Copyright © 2006 John Wiley & Sons, Ltd.