new wear test devices narrow the gap between research and practice
TRANSCRIPT
New wear test devices narrow thegap between research and practiceProject Manager Kati ValtonenTampere University of TechnologyDepartment of Materials ScienceTampere Wear Center
FIMECC DEMAPP Program Final Seminar30.9.2014, Espoo
Wear resistantmaterials and
solutions“Towards
comprehensivecontrol of wear”
Developmentof new wear
resistantmaterials and
characterizationof their
microstructureand properties Development
and applicationof new wear
testingtechniques and
test facilities
Modeling of thewear processeswith increasing
complexity
Analyzing andcombining the
characterization,wear testing,and modeling
results
Development of application oriented wearresearch infrastructure
Challenge:Extreme diversityand complexity ofwear phenomena
Development of application oriented wearresearch infrastructure
Challenge:Extreme diversityand complexity ofwear phenomena
Approach:Combining of
materialscharacterization,wear testing, and
modeling
Wear resistantmaterials and
solutions“Towards
comprehensivecontrol of wear”
Development ofnew wearresistant
materials andcharacterization
of theirmicrostructureand properties
Development andapplication of
new wear testingtechniques and
test facilities
Modeling of thewear processeswith increasing
complexity
Analyzing andcombining the
characterization,wear testing, andmodeling results
Development of application oriented wearresearch infrastructure
Challenge:Extreme diversityand complexity ofwear phenomena
Approach:Combining of
materialscharacterization,wear testing, and
modeling
Progress:Developmentof novel wear
testingmethods and
facilities
Laboratory scale dual pivoted jaw crusherfor studying the mechanisms of abrasivewear during mineral crushingHigh speed slurry-pot type erosion weartester for testing the wear resistant materialsfor industrial solutionsImpeller-tumbler testing device to determinethe effects of impact-abrasion wear in mineralhandling and transportHigh velocity particle impactor for thestudies of the mechanisms of impact erosiondamage and for the numerical model andsimulation verifications
Dual pivoted jaw crusherA novel reduced-size laboratory scalejaw crusher for studying the mechanismsof abrasive wear during mineral crushing– replaces/complements the standardized test
ASTM G 81-83, which has a fixed openingangle and fixed movement between the jaws
– can be used to determine the materialproperties beneficial to wear resistance at anycombination of compressive and slidingabrasion
Key design features:– control of jaw movement without changing the
test geometry, enabling accurate control of thecompression-sliding ratio.
– versatile instrumentation for monitoring thewear processes, including piezoelectric forcesensors, high speed video systems, etc.
Dual pivoted jaw crusher
Compressioncompression/sliding ratio 10:1
Slidingcompression/sliding ratio 1:8
High-speed slurry-pot type erosion testerTesting of wear resistant materialsin high stress erosive or abrasivewear conditions
– dredging pumps– mining applications– loader buckets
Testing of mineral abrasiveness ina slurry or in dry conditionsKey design features:– high rotation speed: up to 2000
rpm (20 m/s in the sample tip)– large abrasive size: 0-10 mm– suitable for testing of metal bars or
plates, thick and thin coatings,elastomers, and hybrid materials
– possibility to edge protection– flow conditions vary in 4 sample
levels ® requires sample rotation
Impeller-Tumbler Impact-Abrasive Wear TesterSimulates wear in mineral handling applications, such as earth movingmachinery and impactor plants.During the test, an impeller with three samples rotates inside a rotatingtumbler filled with gravel.– Impeller rotating speed up to 700 rpm,
tumbler rotating speed up to 120 rpm– Variables: sample angle, gravel size
distribution, type, and amount– One sample is the reference ® changes
in mineral composition controllable
Abrasion TestingScratch testing with natural rockintender to produce simplifiedwear tests with controlled loadsSharp asperities are createdduring the test by fracturing ofthe rockLimitation: every tip is different
Crushing pin-on-disc simulatesmineral crushing and handlingapplicationsContact mode, high loads, largeabrasive size, abrasive type, andthe comminution of the abrasiveform the basis for the testsVariables: disc, abrasive, load
High Velocity Particle Impactor (HVPI)Developed for the model verification and to identify the basic mechanismsinfluencing the impact wear and failure behavior of materialsKey design features:– various angles and impact energies; projectile speed: 30…200 m/s– suitable for various materials: metals, coatings, elastomers, hybrids, ...– projectiles: metallic or ceramic ball bearing balls, cylinders, bullets, and rocks– video recording: high speed camera NAC MEMRECAM up to 80 000 fps or
LaVision StrainMaster 3D DIC systems (high and low rate)
Trap wall
Targetassembly
Speedmeasurement
device Smooth bore
Pressurecontrol
Pressurizedair tank
Specimen
Experimental research plays a key role insolving wear problems
The wear test results have been utilized in thesteel development work at Ruukki Metals.– enhanced understanding of the wear phenomena
was the enabling factor in the improvement of thewear resistance of the new steels.
– results have also been used to help customers toselect the best materials for their applications.
Wide range of wear resistant steels and othernovel materials developed in the project werewear tested as prospective materials forMetso’s crushing and grinding systems.The developed dual pivoted jaw crusher hasproven a valuable tool for better understandingof the combined effects of different crushingparameters and mineral properties.– will be used for example in the process planning
and development of process optimization tools atMetso.
Contact
Kati ValtonenTampere University of TechnologyDepartment of Materials ScienceTampere Wear Center
http://www.tut.fi/twc/en
FIMECC DEMAPP programhttp://www.fimecc.com/content/demapp-demanding-applications-program
DEMAPP Program - Final Seminar 30.9.2014