Fretting Wear Behavior of The Hardfaced Structural Steel Under Corrosive Environment

Fretting Wear Behavior of The Hardfaced Structural Steel Under Corrosive Environment

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Available online at www.sciencedirect.com

ScienceDirect Materials Today: Proceedings 15 (2019) 96–102

www.materialstoday.com/proceedings

FCCM-2018

Fretting Wear Behavior of The Hardfaced Structural Steel Under Corrosive Environment Mahesh Patela, Sangam Sangrala, Kulkarni Achyutha, M. Jayaprakashb a

b

Research Student, Discipline of Metallurgy Engineering and Materials science, IIT Indore, Indore, 453552, India Assistant Professor, Discipline of Metallurgy Engineering and Materials science, IIT Indore, Indore, 453552, India

Email Id: [email protected] Abstract In this study, effect of hard facing on fretting wear behavior of structural steel under various environments has been investigated. As the first step hard facing of austenitic stainless steel AISI 308L was performed on structural steel by arc welding, microstructure and mechanical properties were investigated. In the second step, fretting wear test was carried out with different loads (10N, 20N and 30N) under various environments [temperature (27°C, 75°C, 125°C &175°C) and Salt water environment]. The result showed that the structural steel could be hardfaced by austenitic stainless steel AISI 308L with a reasonable quality of bonding by arc welding. Hardness of the structural steel enhanced by 30% by hardfacing of 308L. The fretting wear test result showed that in structural steel wear volume loss is significantly higher than the hardfaced steel under all environments used in the present study. Finally, an empirical relationship was also developed to predict the wear loss theoretically as a function of temperature & applied load at 3-meter sliding distance. © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Frontiers in Corrosion Control of Materials, FCCM-2018. Keywords: hardfacing, steel; environmental effect; wear; corrosion

1. Introduction Many structural components generally fail to perform their function, not because of fracture, but due to wear, as consequent, the dimension and functionality of this component could be lost. In apart from the various type of wear, fretting wear often happens in any assembly of the structural & engineering component due to existent vibration. Fretting is the oscillatory motion with a very small amplitude between two parts which are having in contact pair, as consequents of these relative motion, the materials at the contact surface is damage. Such damages of materials called as fretting wear [1,2]. fretting wear (complex mechanism includes oxidative, adhesive, surface fatigue and abrasive) is influence by a various factor like; environmental condition and material properties [3]. The mechanism 2214-7853 © 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of Frontiers in Corrosion Control of Materials, FCCM-2018.

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of debris formation, ejection from the contacting surface and the retention on the surface also affect the fretting wear [1,4]. This type of wear encountered in all quasi-static loaded various assemblies such as bio-implant (especially in Orthopaedic), bearing races, power plant machinery, shafts, keys, IC engine block, cranes, turbine blade roots, electrical contacts, nuclear reactor components, etc. [5]. Fretting wear cannot be completely eliminated but it can be reduced to some extent by applying lubrication (limited application) (or) reducing the relative motion (which is practically very difficult) or surface engineering[2-3]. Surface engineering (Coatings, hard facing and etc.) is one of the effective method to enhance the fretting wear resistance. The hardfacing is one of the ways to reduce the fretting wear by applying the hard material over the base material. Hardfacing by welding is usually employed in a number of applications such as petrochemical, food industry or mining to improve the life of various engineering parts [6]. The coating of the hard material on the substrate to enhance the wear and corrosion properties of the component. In these way, the various welding technique is used; open arc welding, SMAW, TIG, MIG also some sophisticated processes also used, like laser or thermal spray coating (especially HVOF coating), but these techniques are required more energy and skilled labor [7]. Apart from above mention technique, the arc welding is more simplest and most used way to hardfacing of various structure and cultivator shovels [8-9]. Austenitic stainless steel has excellence in corrosion and wear resistance properties at the severe condition and apart from these, the weldability between structural steel and stainless steel is impressive. There are many studies on hard facing of stainless steel over structural steels [ 10-14], and their wear behavior. However, there is no or limited studies on fretting wear behavior of hard faced stainless steel on structural steel on severe environments. In the present study hard facing of Austenitic stainless steel over structural steel was carried out by arc welding for the and the fretting wear test different environments. The results were discussed based on the wear volume loss measurement and coefficient of friction. Also, theoretical expression was developed to predict calculate the wear volume loss of hard faced austenitic stainless steel on structural steel at different environments. 2. Experiment 2.1Materials and hardfacing: In this study, the austenitic stainless steel AISI 308L was used as an electrode (3mm diameter) for arc welding and the structural steel in the form of plate (7mm thickness) as the substrate material (as shown in Fig.1a). The chemical composition of the austenitic stainless steel AISI 308L and structural steel used in the present study are shown in the Table 1. The hard facing was done under room temperature atmosphere using arc welding (Toshon Arc Welding Machine) with straight polarities at 145A current with constant voltage. Before hardfacing the substrate (structural steel) was cleaned with acetone and preheated at 150°C to remove the contaminate. During hard facing, the welding speed of 0.3 meters per minute was used for deposition of the austenitic steel over structural steel substrate. Table. 1 Chemical composition (weight %) of austenitic stainless steel AISI 308L and structural steel.

Element 308L steel Structural steel

Fe

Cr

Ni

Mn

Si

P

C

S

Balance

19-21

10-12

2

1

0.045

0.03

0.03

¯

¯

1.03

0.003

0.040

0.25 - 0.290

0.050

Balance

Cu ¯ 0.002

2.2Micro structure and Mechanical property evaluation Hardness test was done using Rockwell hardness tester on scale A at a different location at room temperature. For optical microscopy the cross-section of the samples was cut by wire EDM machine and then polished up to 2000 grade emery paper and etched with Nitol solution for 20 Sec. The fretting wear test was performed in fretting wear

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tester machine (reciprocating wear test machine). The test was conducted at a different load (10, 20, 30N) and different environments (high temperature and corrosive) for sliding distance of 3 meter. The high temperature environment was created by using hot blower. The temperature was monitored using IR non-contact optical pyrometer. Different temperature (room temperature-27°C, 75°C, 125°C and 175°C) to see the effect of temperature on the wear rate and instantly coefficient of friction (COF) of hardfaced steel. During the test temperature fluctuations were with in ±5°C. To do test at corrosive environment, the corrosive atmosphere was created by using the NaCl solution. At first the test samples were pretreated by soaking in the NaCl solution for 100 hours at room temperature. Fretting wear tests were carried out with the pretreated samples under NaCl solution environment. The setup of for creating the NaCl environment during fretting wear test were made inhouse. During the test the NaCl solution was made to pour drop by drop with a discharge rate of 0.36 litter per hour. The schematic of the fretting wear under corrosive environment is shown in Fig. 1(b).

Fig.1 Shows (a) cross-section view of hardfaced sample and (b) Setup for the corrosive environment of fretting wear test.

Fig.2 Shows the optical micrograph of hardfaced steel at 200X.

3. Results and discussion 3.1Hardfacing Figure 2 shows cross sectional view of the hardfaced Austenitic stainless steel AISI 308L on the structural steel observed through optical microscope. Due to good welding compatibility between the Austenitic stainless steel AISI 308L and the structural steel, bonding between them was good. The hardfacing thickness was 3.5±0.5 mm was achieved by arc welding (as shown in figure 1a).

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3.2Mechanical Properties The surface hardness was measured by the Rockwell hardness tester at three different location (substrate, interface, and coating) of various sample at room temperature by scale-A. It was found that the average hardness of the austenitic stainless steel, structural steel and interface were 62.31, 43.35 and 52.475 RC-A respectively (as shown in Table 2). The result showed that the hardness of structural steel enhanced to about 30% of by hard facing of austenitic stainless steel. 3.3Effect of load on volume loss The Fig. 3 shows that the wear volume loss increases linearly with an increase in applied load for both hardfaced steel and structural steel. This behaviour is due to the increase in friction force with increase in load. Results also showed that the wear volume loss in hardfaced steel is significantly less as compare to structural steel. Hence, due to hardfacing, wear resistance has significantly increased.

Fig.3. Show the volume loss comparison of hardfaced steel with structural steel. Table 2 Mechanical properties of hardfaced steel. Hardness

Tensile Strength

RC-A

KSI

MPa

62.31±2

116±3

800±18

Interface

52.475±2

82.5±3

569±18

Structural Steel

43.35±2

67.5±3

465±18

SN

Elements

1

AISI 308L Steel

2 3

3.4Effect of Temperature on fretting wear In the Fig.4, it has been observed that with an increase in temperature the wear volume loss decreases. It is mentioned in the literature [ 4-8], the wear rate was influenced by temperature in two different ways, (1) decreasing of COF and (2) decrement in mechanical properties. As increases temperature oxidation layer form on the surface which act as lubricants and the surface energy of debris increases with temperature which promotes the more adhesion between debris particle to surface. As result, the coefficient of friction decreases 20 to 30 % in steel [1]. In another hand, at higher temperature the considerable decrement occurs in mechanical properties like hardness, strength etc. as result, the surface was more prone to wear.

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It can be observed form the figure 5 the instantaneous coefficient of friction reduced drastically as temperature increases. Other researchers also reported that [1-3] for steel the coefficient of friction COF values dominate more on wear rate as compare to the decrement in mechanical properties at a temperature lower than 450°C. Hence, the steel has lower wear rate at a temperature lower than 450°C. An empirical relationship can also have developed to predict the wear volume loss theoretically at given load and temperature. In figure 4, it was observed that the slopes of the linear equation are almost similar and may take an average slope from all plots. The constant as function of temperature with the best fitted linear equation (as shown in figure 6). Hence from figure 4 and 6 the empirical correlation between Wear Volume, applied load and temperature may be expressed through the following relations: . . (1) Where, L=Applied load in Newton T= Temperature in °C From using above empirical relationship (Equation 1), we would predict the volume loss theoretical for sliding distance of 3m at given surrounding temperature & load.

Fig. 4 Shows the wear rate versus applied load at a different temperature.

Fig. 5 Show the coefficient of friction Vs no. of cycles at a different temperature.

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Fig. 6 Show the relation between intercept constant Vs Temperature.

3.5 Effect of corrosion on fretting wear The results of fretting wear tests under corrosion environment is shown in Fig. 7. As seen from the figure, the wear volume loss in case of AISI 308L steel is negligible as compared to the same material at without corrosive environment (as shown in figure 7). But in case of structural steel, the surface damage is more worn and shows a significant difference in wear volume loss as compared to specimen without corrosion. It is due to the fact that, the AISI 308L steel has more corrosion resistance.

Fig. 7 Shows the effect of corrosion on austenitic stainless steel (a) and structural steel (b).

4. Conclusion: The following conclusions can be drawn from the present studiesi) ii) iii) iv)

Hardfacing of AISI 308L steel can be successfully deposited by arc welding on structural steel and it increased hardness by 30% as compare to structural steel. Wear volume loss decrease significantly with increases in the temperature. Due to an increasing temperature, the coefficient of friction (COF) dominates more than the decrement in material properties. Hardfaced of AISI 308L on structural steel is reduces the considerable wear volume loss in corrosion environment condition. The empirical relationship is also useful to predict the theoretical wear volume loss with given temperature and load at sliding distance of 3m.

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Acknowledgements The authors would like to thank the Department of Science and Technology for providing stipend during this research work. References [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15]

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