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Effect of Impingement Angle and Erodent Temperature on Erosion Wear
Behavior of Bamboo Fiber Reinforced Epoxy Composites
Sandhyarani Biswas1*
Alok Satapathy1
Amar Patnaik2
Mechanical Engineering Department
1National Institute of Technology, Rourkela-769008, India
2National Institute of Technology, Hamirpur-177005, India
ABSTACT
In the present study, dry silica sand of different particle sizes (300µm, 450µm
and 600µm) are used as erodent. The samples are cleaned in acetone, dried and
weighed to an accuracy of 0.1 mg before and after the erosion trials using a
precision electronic balance. The weight loss is recorded for subsequent
calculation of erosion rate. The ratio of the weight loss to the weight of the
eroding particles causing the loss is then computed as a dimensionless
incremental erosion rate. The process is repeated till the erosion rate attains a
constant value called steady state erosion rate.
Keywards: Solid particle erosion; Impingement angle; Erodent temperature; Bamboo fiber;
Filler
It is seen, in this figure, that for all the composite samples, the erosion rates remain almost
unaffected by the change in erodent temperature from ambient to 400C.
350
Un filled composite
20wt% RM
20wt% CS
20wt% Alumina
20wt% SiC
300
Erosion rate (mg/kg )
For a composite material, its surface damage by solid particle erosion depends on many
factors. One of the most important characteristics of erosion is the variation of erosion rate
with impingement angle. Determining the effect of the impingement angle on erosion is the
most sensitive way of studying the mechanism of erosion. The erosion rate is also greatly
affected by the erodent temperature. In the present work a series of systematic erosion tests
were carried out to investigate the influence of impingement angle and erodent temperature
on erosion mechanisms of bamboo fiber reinforced epoxy composites using an erosion test
rig. Bamboo fiber reinforced epoxy composites are fabricated using red mud, copper slag,
Al2O3 and SiC particles as filler materials. The erosion rates of these composites have been
evaluated at different impingement angles (15-90°) and at different erodent temperatures
(30-60°C) and the conclusions drawn from the above investigation are discussed.
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EXPERIMENTAL DETAILS
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Composite Fabrication
Table 1. Designation and detailed composition of the composites
Designation
Z1
Z2
Z3
Z4
Z5
Z6
Z7
Z8
Z9
Composition
Epoxy +50wt% bamboo fiber
Epoxy +50wt% bamboo fiber + 10wt% Red mud
Epoxy +50wt% bamboo fiber +20wt% Red mud
Epoxy +50wt% bamboo fiber +10wt% Copper slag
Epoxy +50wt% bamboo fiber +20wt% Copper slag
Epoxy +50wt% bamboo fiber +10wt% Alumina
Epoxy +50wt% bamboo fiber +20wt% Alumina
Epoxy +50wt% bamboo fiber +10wt% SiC
Epoxy +50wt% bamboo fiber +20wt% SiC
The solid particle erosion experiments are carried out as per ASTM G76 using a
standard erosion test rig. The test rig consists of an air compressor, an air
drying unit, a conveyor belt-type particle feeder and an air particle mixing and
accelerating chamber. The dried and compressed air is then mixed with the
silica sand which is fed constantly by a conveyor belt feeder into the mixing
chamber and then accelerated by passing the mixture through a convergent
brass nozzle of 3 mm internal diameter. The set up is capable of creating
reproducible erosive situations for assessing erosion wear resistance of the
composite samples. The erodent particles impact the specimen which can be
held at different angles with respect to the direction of erodent flow. The apparatus
is equipped with a heater which can regulate and maintain the erodent temperature at any
pre-determined fixed value during an erosion trial.
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Figure 3. Effect of erodent temperature on the erosion wear rate of the composites
CONCLUSIONS
Figure 1. Schematic diagram of an erosion test rig
RESULT AND DISCUSSION
Steady state erosion (Effect of impingement angle of erosion rate)
The variations of steady-state erosion rates of bamboo-epoxy and glass-epoxy composites
filled with red mud particulates with the angle of impingement are presented in Fig. 2. The
erosion behavior of materials is broadly classified in the literature as ductile and brittle
depending on the variation of erosion rate with impact angle. Ductile behavior is
characterized by maximum erosion at low impact angles in the range o f 10–300. On the other
hand, if maximum erosion occurs at α = 900, then the behavior is brittle. However, reinforced
composites have been found to exhibit semi-ductile behavior with maximum erosion rate at
intermediate angles typically in the range of 45–600 [1]. In the present study, the variation of
erosion wear rate of the composites with impingement angle is studied by conducting
experiments under specified operating conditions. The result shows the peak erosion taking
place at an impingement angle of 600 for the unfilled as well as the red mud (RM) and
alumina filled bamboo-epoxy composites, whereas composite samples filled with copper slag,
the maximum erosion rate is recorded at an impingement angle of 450 under similar
experimental conditions. However, composite samples filled with SiC, the maximum erosion
rate is recorded at an impingement angle of 750.This clearly indicates that these composites
respond to solid particle impact neither in a purely ductile nor in a purely brittle manner. This
behaviour can be termed as semi-ductile in nature which is in agreement with the trend
observed by previous investigators [1].
This study on the erosion behaviour of particulated filled epoxy composites with
bamboo reinforcement leads to the following conclusions:
1. Hybrid composites suitable for applications in highly erosive environments
can be prepared by reinforcement of bamboo fibers and filling of micro-sized
fillers such as alumina, SiC, red mud and copper slag particles in epoxy
resin.
2. Study of influence of impingement angle on erosion rate of the composites
filled with different weight percentage of particulates reveal their semi-ductile
nature with respect to erosion wear. The result shows the peak erosion taking place
at an impingement angle of 600 for the unfilled as well as the red mud (RM) and alumina
filled bamboo-epoxy composites, whereas composite samples filled with copper slag, the
maximum erosion rate is recorded at an impingement angle of 450 under similar
experimental conditions. However, composite samples filled with SiC, the maximum
erosion rate is recorded at an impingement angle of 750.This clearly indicates that these
composites respond to solid particle impact neither in a purely ductile nor in a purely
brittle manner. This behaviour can be termed as semi-ductile in nature. The erosion
rate is also greatly affected by the erodent temperature.
3. For all the composite samples, the erosion rates remain almost unaffected by the change
in erodent temperature from ambient to 400C.
4. Possible use of these composites in components such as pipes carrying coal
dust, helicopter fan blades, industrial fans, desert structures, low cost
housing, etc. is recommended. In future, this study can be extended to new
hybrid composites using other potential fillers and the resulting experimental
findings can be similarly analyzed.
450
Un filled composite
20wt% RM
20wt% CS
20wt% Alumina
20wt% SiC
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REFERENCES
10wt% RM
10wt% CS
10wt% Alumina
10wt% SiC
1. Ruff A W, Ives L K. Measurement of solid particle velocity in erosive wear. Wear 1975; 35
(1): 195-199.
List of Materials used in the present work
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Erosion test apparatus
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Erodent temperature (Degree-C)
Erosion rate (mg/kg )
The fabrication of the various composite materials is carried out through the
hand lay-up technique. Roving bi-directional bamboo mats are reinforced in
particulate filled epoxy (LY 556) composites. The epoxy resin and the hardener
(HY951) are supplied by Ciba Geigy India Ltd. Four different fillers such as:
copper slag, red mud, alumina and Silicon carbide are used in this study.
Copper slag collected from the plant site of Hindustan Copper Limited, at
Ghatsila, India. Red mud collected from NALCO aluminium refinery at
Damanjodi, India. Aluminium oxide and silicon carbide powders of similar size
range are obtained from NICE Ltd India. All the four fillers are sieved to a
particle size range of 80-100 μm. The average thickness of bamboo fibers is
about 1.5 mm. The extracted fibers are dried in an oven at 105°C for 72 hours
to remove moisture. Each ply of bamboo-fiber is of dimension 200 × 200 mm2. A
stainless steel mould having dimensions of 210 × 210 × 40 mm3 is used. The
low temperature curing epoxy resin and corresponding hardener are mixed in a
ratio of 10:1 by weight as recommended. The composites prepared for this
study are designated as Z1, Z2, Z3, Z4, Z5, Z6, Z7, Z8 and Z9 respectively. The
detailed compositions along with the designation are presented in Table 1. The
cast of each composite is cured under a load of about 50 kg for 24 hours before
it removed from the mould. Then this cast is post cured in the air for another 24
hours after removing out of the mould. Specimens of suitable dimension are cut
using a diamond cutter for erosion testing. Utmost care has been taken to
maintain uniformity and homogeneity of the composite.
10wt% RM
10wt% CS
10wt% Alumina
10wt% SiC
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30
45
60
75
90
Filler content (%)
Figure 2 . Effect of impingement angle on the erosion wear rate of the
composites
Effect of erodent temperature on erosion rate
Similarly, the variation of erosion rate of unfilled and red mud filled composites with
erodent temperature is shown in Fig. 3. This figure also presents the erosion rate
of all the particulate filled composites with bamboo reinforcement for different
erodent temperatures. Erosion trials are conducted at seven different temperatures
under normal impact condition.
Matrix:
EPOXY
Fiber:
Natural Fiber : Bamboo
Particulate Fillers:
Red Mud
Copper Slag
Alumina
Silicon Carbide