valtonen nordtrib14 presentation_final

15
EROSION WEAR OF GLASS FIBRE REINFORCED VINYL ESTER Reija Suihkonen, Juuso Perolainen, Mari Lindgren*, Kati Valtonen, Niko Ojala, Essi Sarlin, Jyrki Vuorinen Tampere University of Technology Department of Materials Science Tampere Wear Center *Outotec Research Center The 16 th Nordic Symposium on Tribology – NORDTRIB 2014 10 th -13 th June 2014, Aarhus, Denmark

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Page 1: Valtonen nordtrib14 presentation_final

EROSION WEAR OF GLASS FIBREREINFORCED VINYL ESTER

Reija Suihkonen, Juuso Perolainen, Mari Lindgren*,Kati Valtonen, Niko Ojala, Essi Sarlin, Jyrki Vuorinen

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

*Outotec Research Center

The 16th Nordic Symposium on Tribology – NORDTRIB 201410th-13th June 2014, Aarhus, Denmark

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Department of Materials ScienceInternationally high-level know-how on all materials based on

strong interdisciplinary basic research

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Background of the study• Glass fibre reinforced vinyl ester

composites are widely used e.g. in tanks,piping, and ducts– Waste water treatment plants– Chemical processing– Pulp and paper manufacturing

• Demanding environments:– Corrosive (e.g. 5% H2SO4)– Elevated temperatures (close to 100°C)– Erosive wear

• Wear mechanisms in fibre reinforcedpolymers more complicated than inpolymers and metals– Different material components and their

interfaces– Several wear types at the same time (e.g.

abrasion, fatigue, plastic deformation, melting) Outotec OKTOP® Reactors

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High speed slurry-pot wear tester• Comparison of abrasives and their

effects on the wear of different materials• Consists of a motor-run rotating shaft to

which the sample holders are attached infour different levels

• Rotating speeds up to 20 m/s possible• Test parameters:

– 8 samples were tested simultaneously– Wear varies in different levels ® samples

are rotated through all sample levels– Testing time 4 x 10 min– Tested samples (size 35 mm x 35 mm)

were attached to the sample holders bypressing them between two steel frames

– Rotation speed 1400 rpm (12.5 m/s at thetip of the blade)

– Slurry consisted of 10 l tap water andabrasive material (0.5, 1.0, or 3.0 kg).

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Test materials and abrasives• Glass fibre reinforced vinyl ester composite

– Epoxy vinyl ester resin (Derakane Momentum 411-350)– 6 layers of chopped E-glass mat (300 g/m2) & C-glass surface mats (26 g/m2)– Manufactured laminate size 1000 mm x 1000 mm, thickness roughly 3 mm– Post cured in 80°C for four hours– Sample edges were sealed with vinyl ester resin

• Other polymers for comparison:– Natural rubber (NR)– Bromobutyl rubber (BIIR)– Polypropylene (PP)– Polyvinyl chloride (PVC)

• Five different types of abrasives:– Quartz (four different particle sizes)– Chromite (fine and coarse)– Concentrate– Ore– Tailings.

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Abrasivecharacterization

Quartz (125-185 µm)

Quartz (100-600 µm)

Chromite (fine)

Chromite (coarse)

Concentrate

Ore

Tailings

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Small variations in quartz particle sizedid not have a marked effect on theweight loss of fibre reinforced vinyl ester• The highest erosion rate was obtained with coarse quartz with large (100 -

600 µm) particle size• Coarse chromite (D50 57 µm) was more abrasive than quartz with larger

particle size (D50 80-119 µm)

1.0 kg, 40 min, 1400 rpm

Large, round holes and long,wide, and randomly orientedgrooves

Page 8: Valtonen nordtrib14 presentation_final

Erosion rate of fibre reinforced vinylester depend markedly on the kineticenergy of the impacting abrasive material• Abrasives with smaller particle size, such as concentrate and ore, were

clearly less erosive• Tailings, with large average particle size but lamellar structure, caused only

moderate erosion rates• VE-FRP had the most

modest erosion resistanceof the tested materials– Brittle fibres in fibre

reinforced vinyl ester• Polypropylene had the

lowest wear rates– Thermoplastic materials

exhibit ductile behaviour• Rubbers can dissipate the

kinetic energy of theabrasives

1.0 kg, 40 min, 1400 rpm

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0

0.5

1

1.5

0 1 2 3

VE-F

RPw

eigh

tlos

s(w

t.%)

Amount of abrasive in the slurry (kg)

Quartz (100-600 µm)

Quartz (125-185 µm)

Tailings

Effect of abrasive concentration onerosion wear results

• No change in the weightloss when the amount ofabrasive was raised from0.5 to 1.0 kg

• When the abrasivecontent in the slurry wasraised to 3.0 kg, a smallincrease in the VE-FRPweight loss can beobserved– high variation in the

results with 3.0 kg ofquartz (100-600 mm)

40 min, 1400 rpm

Page 10: Valtonen nordtrib14 presentation_final

Wear surfacecharacterization• The lower wear, rate the narrower and

shallower are the grooves created in thesample surface– VE-FRP wear surfaces rather smooth after

the erosion test with ore and concentrate– Quartz (125-185 μm) that produced lower

wear than coarse quartz (100-600 μm)causes minor damage to the surface

• Quartz (100-600 μm) causes large, roundholes as well as long, wide, andrandomly oriented grooves to the VE-FRP surface– Severe matrix removal followed by fibre

breaking and debonding– Not only single fibres but fibre bundles

exposed and partially detached from thematrix.

10

Quartz (125-185 µm)

Quartz (100-600 µm)

Concentrate

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Erosion process ofglass fibre reinforcedvinyl ester1. Local removal of the matrix material

– Creation of small holes, craters, andexposed fibres

2. Abrasive particles bombard theexposed fibre surfaces– Generation of small scratches and

pits

3. Fibre fragmentation into several smallparts

4. Detachment of fibres from the matrix– Creation of distinctive, deep tracks

11

2

3

4

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Conclusions

• The erosion wear of glass fibre reinforced vinyl ester depends highlyon the abrasive type, size, hardness, and its kinetic energy

• The coarse quartz with the highest kinetic energy produced thehighest erosion wear– Small variations in quartz particle size did not have a significant effect

on the erosion wear of the glass fibre reinforced vinyl ester• When the erosiveness of finer particles was compared, the wear rate

caused by hard chromite was the highest– Softer abrasives with smaller particle size, such as concentrate and ore,

produced lower wear rates• Glass fibre reinforced vinyl ester has higher erosion wear rate than the

tested rubbers and thermoplastics• The erosion process started with the local removal of the matrix

material and continued with the fibre fragmentation and debondingfrom the matrix.

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The work has been done within FIMECCLIGHT program funded by Tekes and industry

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www.tut.fi/rocktrib

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28th International Conference onSurface Modification Technologies16.-18.6.2014 Tampere

SETEC 14SAMPE Europe Technical Conference& Table Top Exhibition10.-11.9.2014 Vapriikki, Tampere