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Corresponding author. Tel.: +61 3 9252 6173; fax: +61 3 9252 6252.
E-mail address: Jie.Wu@csiro.au (J. Wu).
has beendeveloped[6] that incorporates experimentally measured
erosion data for cylinders in-pipe ow. However, it is clear from
our work thus far that it remains a major challenge to reliably pre-
dict erosion patterns via CFDalone, particularly for highly complex
multiphase ows such as those with time-dependent vortices, and
therefore physical experiments to assess any new design concept
are still required to validate CFD predictions.
Materials are often characterized as either ductile or brittle,
according to their differing erosion rate versus angle of attack
curves [3]. For ductile materials, the erosion rate reaches a max-
imum value at impact angles of 1030
.
Erosion of metals is the major problemaddressed by this paper,
as metals are widely used in the mineral processing industry. Met-
als suchas mildsteels, aluminumandtitaniumoftenexhibit ductile
or mixed ductile/brittle behavior [1]. Thus it is reasonable to con-
sider using paint as a model material for visualizing the erosions
on metals, as paint exhibits similar ductile behavior [7].
Wuet al. [8] andNoui-Mehidi et al. [9] haveshownthefeasibility
of using the multilayer paint technique to produce accelerated and
highly visible erosion damage in various ow geometries, to assist
inthe development of improvedgeometrical designs that minimize
erosion. This paper expands onthese previous results, and provides
a summary of the basic technical procedures and an error assess-
ment of the paint modeling technique, as well as further examples
of its use in developing improved designs.
0043-1648/$ see front matter 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2011.01.016
J. Wu et al. / Wear 270 (2011) 598605 599
Fig. 1. Typical examples of erosion developed in minerals industry equipment: (a)
axial ow impeller after operating in a slurry autoclave; (b) slurry screen after a
ltration operation; and (c) cooling plate after operating in a slurry ow.
The objective of this paper is to present erosion solution cases,
developed from applying the paint modeling technical through
laboratory or site testing, with validation by error analysis and
cylindrical sample measurements.
Fig. 3. Schematic of experimental test rig: air/solids ow test loop, pipe section
diameter 100mm, typical test section air velocity 80m/s. Robushi E106 75kW
blower. Temperature and pressure are ambient. Solid particles used were sands,
glass particles of 50500m.
2. Experimental setup and technique
2.1. Erosion test rigs
Two experimental ow loops were set up, as shown schemati-
cally in Figs. 2 and 3. The slurry owtest loop (Fig. 2), consisted of a
3000-L agitated slurry holding tank, a Warman 32 slurry pump,
an Emerson magnetic owmeter. Typically silica sand (Gareld
sand) of d
50
=200m were used as erodent particles. Tap water
was used as the liquid phase. Asolid concentration of 7% (w/w) was
used in the tests. Sand/water slurries were recirculated at typical
velocity range of 010m/s. The test section pipe ID was 53mm.
In the air/solids ow test loop (Fig. 3), sand or glass particles
of d
50
=50, 500m diameters were recirculated at a maximum
velocity of 80m/s, using a Robushi E106 75kW blower. The solids
were fed and removed through a cyclone separation/hopper feed
system. For these experiments, the nominal diameter of the test
pipe sections was 100mm.
A mixing tank similar to that depicted in Fig. 2 was also used
to study erosion development on rotating impellers. Mixing tank
diameter was 0.390m, and agitator speed typically from 0 to
500rpm. Agitator diameter was in the range 0.1600.190m. Sands
or glass particles with d
50
in the range of 100200m were typi-
cally used in the mixing tank.
2.2. Paint application procedure
For the purpose of illustration, our practice of applying spray
paint for erosion modeling is introduced here. To produce a quali-
tative illustration of erosion using the multilayer paint technique,
the paint had to be evenly distributed so that thickness variation
Fig. 2. Schematic of experimental test rig: slurry owtest loop. This rig consisted of a 3000-L agitated slurry holding tank, a Warman 32 slurry pump, an Emerson magnetic
owmeter, and associated pipe ID of 53mm.
600 J. Wu et al. / Wear 270 (2011) 598605
across the material surface was minimal. It was therefore necessary
to reduce any gravity-induced ow of wet paint lm on a mate-
rial surface, or part thereof, inclined to the horizontal plane. This
was achieved by using a very ne paint spray, and applying the
successive layers at intervals that allowed drying between each
application.
Typically, multiple layers of paint each 4060m thick were
sprayed onto a test material surface using a paint air-gun system.
A probe, e.g. a Fischer Dualscope MP20 thickness gauge, or other
was used to measure the depth of each paint layer, as well as the
total paint thickness before and after each test. Paint lmthickness
measurements allowanassessment of uniformity of the painting. It
can also provide a quantitative measure, which is helpful in some
cases.
2.3. Erosion modeling
To validate the paint modeling technique to a variety of
materials, more accurate measurements of the effect of particle
impingement angle were conducted. These useda similar approach
to [6] where a cylindrical metal sample (10mm diameter) was
mountedacross aslurrypipeow(50mmindiameter) that enabled
the full range of particle impact angles to be tested in a single
experiment.
Erosion measurements of metal samples were conducted using
a purpose-built erosion measurement facility similar to that
described in [10], consisting of a collet chuck for holding cylindri-
cal samples, a 200-step stepper motor drive and a Schaevitz gauge
head (precise linear variable differential transducer (LVDT)).
Painted cylinders were also tested for comparison with the
metallic samples. Paint thickness measurements on the cylindrical
samples were made in a separate rig using the Fischer Dualscope
MP20 gauge, which was mounted in a drill chuck so that the probe
could be traversed around the cylindrical sample.
3. Results
3.1. Validating paint erosion modeling technique
Fig. 4(a) shows the results of a test on a rotating cylindrical rod
placed horizontally in a slurry pot (Fig. 4(b)). It can be seen that
a double-wedge erosion pattern developed along the rod surface.
Note that the angular location of the axes (approximately 2030