Study of materials test methods for wear resistance in oil and mining industry

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This paper proves that the principal wear mechanism is abrasive and shock-abrasive wear; and analyzes materials test methods and techniques for wear rate identification.

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International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 03, March 2019, pp. 1781–1791, Article ID: IJMET_10_04_180 Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3 ISSN Print: 0976-6340 and ISSN Online: 0976-6359 © IAEME Publication Scopus Indexed STUDY OF MATERIALS TEST METHODS FOR WEAR RESISTANCE IN OIL AND MINING INDUSTRY Yury Dukhnenko Department of Lithology National University of Oil and Gas Gubkin University, Russia ABSTRACT The main cause of damage to oil and gas equipment is wear. This paper proves that the principal wear mechanism is abrasive and shock-abrasive wear; and analyzes materials test methods and techniques for wear rate identification. The author considers standardized and non-standardized methods and establishes that despite a large number of materials test methods, we don’t have a unique one for adequate assessment of wear resistance in metals. It is concluded that selection of test methods depends on working conditions of the equipment and use of different types of wear to assess resistance of metals. Key words: Wear, wear resistance, metallic materials, rocks, abrasivity, abrasive wear, shock-abrasive wear Cite this Article: Yury Dukhnenko, Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry, International Journal of Mechanical Engineering and Technology 10(3), 2019, pp. 1781–1791. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=3 1. INTRODUCTION Modern world development requires a great amount of natural resources. Extraction and processing of natural resources is impossible without highly efficient equipment with improved performance [1-5]. The rate of natural resources extraction is limited by a number of factors associated with mining and geological conditions, environmental safety, equipment performance, etc. [6-17] High-tech equipment applied in minerals extraction can greatly influence the mining economy. One of the main factors affecting performance of machines and equipment is their reliability. Reliability of equipment, to a great extent, depends on durability of its components. We can improve durability of various components by changing their design, using new, more durable and wear-resistant materials or finding special technological solutions to improve these characteristics in the applied materials. A method to increase strength and durability of materials in machine parts should be selected by taking into account analysis of operational conditions of equipment. The same material processing technology may have different effects on wear resistance of a certain material depending on its wear conditions. http://www.iaeme.com/IJMET/index.asp 1781 editor@iaeme.com
Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry Most drilling, oil and gas equipment is subject to significant static and dynamic loads, as well as intensive wear and corrosion in the course of operation. Apart from that, a large number of parts operate in abrasive and corrosive environments at high temperatures. In some regions, temperature can differ from +50 ºC to –50 ºC. Also, as the drilling wells deepen, the bottom- hole temperature increases, so the main parts of drilling tools operate at the temperature of 200 ÷300 ºC. 2. TEST METHODS 2.1. Standardized methods Operating in highly aggressive environments, parts of mining equipment are subject to significant wear, which, in turn, leads to their failure [18-27]. The main type of wear in equipment and machines of the oil and mining industry is wear caused by abrasive particles. One of the groundbreakers in the study of wear mechanism was Professor M.M. Khrushchev. It was he or researchers under his supervision who formulated basic principles of wear process. In particular, a great contribution to the study of abrasive wear processes in machines of mining and agricultural industries was made by Professor M.M. Tenenbaum, M.A. Babichev, Dr.-Ing. Karl-Heinz ZumGahr et al. [28, 29]. Wear of metallic materials can follow different pattern and depend on many factors. Quite often, wear of a drilling tool combines several mechanisms: micro-cutting, peeling, fatigue failure, chips, etc. [29]. It has been proven [28-31] that destruction of materials in abrasive wear is caused by cutting or scratching effect of solid particles. Paper [32] summarizes works of various researchers who studied wear resistance of materials by sclerometric methods, namely, determined scratch resistance and hardness during indentation. The data obtained for pure metals proved that hardness and scratch resistance has a straight dependency. However, for steels with different carbon content or alloyed steels, this dependency is non-linear. Currently, scratching is not among standard methods for determining wear resistance in materials. However, a foreign standard ASTM G171 - 03 (2009) e2, which determines the wear resistance of materials and coatings is a test method for scratch hardness of materials [32]. In Russia we have a similar national standard GOST 21318-75 "Measurement of micro-hardness by scratch diamond instruments". Figure 1. Standard Test Method for materials wear against a loosely fixed abrasive http://www.iaeme.com/IJMET/index.asp 1782 editor@iaeme.com
Yury Dukhnenko In accordance with GOST 30480-97 and GOST 23.208-79, a standardized method of testing materials for wear resistance is friction against loosely fixed abrasive particles (Figure 1). The method is based on the Brinell hardness test method, in which specimens of the test and reference materials are worn with abrasive particles fed into the friction zone and pressed to the specimen by a rotating rubber roller. In this case assessment of wear is relative in nature [33]. A device with a similar principle is used in the ASTM G65 standard, the only difference is that the specimen is pressed against the roller in a vertical position. Test for abrasive wear against rigidly fixed abrasive particles is covered by GOST 17367- 71 “Metals. Method of abrasion test by friction against embedded arrogant grain". The idea behind this method is that the test and reference specimens are rubbed against the surface with embedded arrogant grain (abrasive sandpaper) under static load and no heat; then the results are compared. For reference specimens the method usually uses technically pure annealed aluminum (a test specimen has hardness less than HV150) or technically pure annealed iron (a test specimen has hardness less than HV150). When materials are tested for gas and abrasion wear, another standard is applied - GOST 23.201-78 “Products wear resistance assurance. Gas abrasive wear testing of materials and coatings with centrifugal accelerator”. The method is based on simultaneous exposure of the testing and reference specimens to a solid particles flow generated by a centrifugal accelerator with standard sizes of working elements under fixed test conditions; the wear rate in the test and reference specimens is measured, then the wear resistance of the material is assessed by comparing it with the reference specimen wear. Standard ASTM G76 offers another method. The air flow passes through a mixer, captures abrasive mixture particles (abrasive) and is fed through a nozzle (nozzle) to the test specimen (test specimen). Speed of the particles flow depends on the air pressure. Depending on experimental conditions, the inclination angle of the test specimen may vary (Figure 2). When testing materials for shock-abrasive wear, researchers usually apply GOST 23.207- 79 “Ensuring of wear resistance of products. Testing of engineering, materials for impact abrasive wear”. In this method the specimen is repeatedly hammered on a fixed anvil through a layer of solid abrasive particles, with a given impact energy, speed and frequency of impacts, then relative wear resistance of the material is assessed by comparing wear of the test and reference specimens tested in identical conditions (Figure 3). Figure 2. Standard Test Method for gas abrasive wear under ASTM G76 http://www.iaeme.com/IJMET/index.asp 1783 editor@iaeme.com
Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry Figure 3. Standard Test Method for Shock-abrasive wear One of the standard techniques deliberately developed for the mining industry is ASTM G81. The principle of this method is based on using of a reduced size jaw-crusher (Figure 4). The test specimen is a lining plate of the movable crusher jaw (test plates). When crushing the rock, the movable plate is worn by gouging. This method is comparative, and can be used to compare different types of lining plates with a reference specimen. It makes sense to use this method in order to select the most wear-resistant material of the crushers jaws, linings of bodies and ball mills, teeth of excavator buckets. In order to test very hard and durable coatings for abrasive resistance, a contour method was developed and ASTM G174 was created. In this test method a test specimen with the coating is pressed against an abrasive closed loop. A closed loop is a tape with fixed abrasive particles with a size of 30 or 3 microns. When the tape is rotated, the coating is rubbed. Another method ASTM G132 uses a drum with sandpaper attached to it as an abrasive wear test. Here they use garnet as an abrasive, rather than aluminum oxide or sand. Garnet is more preferable here because its hardness is comparable with most of mineral inclusions or rocks. In this experiment the test specimen is pressed and moves along the rotating drum, this ensures contacts of the specimen with a new abrasive surface at each moment of time. Relative wear resistance is compared with the reference specimen as an indicator of wear resistance. Figure 4. Standard Test Method for Gouging Abrasion Test http://www.iaeme.com/IJMET/index.asp 1784 editor@iaeme.com
Yury Dukhnenko ASTM B611 test method has a similar principle to ASTM G65. The only difference of this method is that the wheel is made of steel and is placed in slurry of water and aluminum oxide particles together with the test specimen. This method is used in testing cemented carbides for abrasion resistance [32]. ASTM G105 method is based on testing specimens in a liquid-sand mixture for 1 hour. Test time may vary depending on the type of material tested. Also, similar to ASTM G65, it uses a rubber wheel, against which the test specimen is pressed (Figure 5). Figure 5. Standard Test Method for hydro-abrasive wear of metal specimens under ASTM B105 In addition to standardized methods, there are a large number of other methods aimed at testing materials for abrasive wear; such methods were developed under the standardized methods. Most of these techniques are described in [29, 31, 32]. One of the first Russian wear test methods, still widely applied today, is the method developed by M.M. Khrushchov and M.A. Babichev; it tests wear of the specimens against the sand paper abrasive surface in the X4-B device [29]. During the test a cylindrical specimen is pressed against the sandpaper abrasive surface. When the disk rotates and the cylinder simultaneously slides, the specimen moves in a spiral so that at each moment of time 50% of its working surface rubs against a new abrasive surface, which ensures homogeneous and uniform abrasive properties of the abrading surface. The largest radial movement of the specimen is 100 mm. Movement of the specimen is reversible [34]. The tests are made at relatively low loads (P = 3 N). The results are presented as the ratio of wear in the reference material to wear in the tested material. Wear is manifested as a changed linear size of the specimen (in this case, height) during the test and is determined by measuring height of the specimen before and after the test. Wear can also be determined by weight reduction - weighing specimens before and after the test on an analytical balance [34]. A similar method is used in the ASTM G99-05 method. Another method to study metals wear that occurs due to operating conditions of the ripping bars in soil-tilling and earthmoving machines is the test method for abrasive compact wear, for example, using a screw extruder [34]. The abrasive mass is loaded into a hopper, then fed into a cylindrical chamber and, compacted by the screw, is squeezed out towards the rotating specimen. The test specimen has a blade shape and is mounted on a faceplate, which rotates at a predetermined number of revolutions during the test. The shape of the specimen is selected as a blade in order to make the test conditions as close as possible to real conditions of interaction between the ripping bar and the abrasive medium. During the test, the abrasive mass extruded by the screw towards the http://www.iaeme.com/IJMET/index.asp 1785 editor@iaeme.com
Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry rotating specimen is cut into a metal box. Wear is determined by measuring linear dimensions of the specimens before and after the test. 3.2. Non-Standardized Test Methods Paper [32] gives a summary of standardized methods for testing abrasion resistance (Figure 6). For instance, the author highlights several basic test methods for wear resistance: when two disks interact in an abrasive mass (Disk Vs Disk); rubber wheel and dry sand (Dry sand / rubber wheel); movement of a specimen under stress along a loose abrasive (high stress abrasion); movement of a specimen under stress along a fixed abrasive (abrasive paper); specimen wear by milling (wheel with “molded-in” abrasive); abrasion of specimen in the abrasive mass (two body abrasion tests). Figure 6. Various abrasive wear test methods Works [35-40] describe tests of 110G13L and 30HGSA steel for abrasive wear (Figure 7) using a modified method of L.I. Baron - A.V. Kuznetsova. A steel specimen was pre-weighed on an analytical balance (weighing accuracy 0.1 mg), secured onto a spindle chuck of the machine, and pressed with a constant force to the surface of the ore plate. For 60-120 s, the specimen was worn against the abrasive surface. At the end of the test, the sample was cleaned from wastes, reweighed, and the weight loss was determined. The same specimen underwent a series of 5 - 7 tests. Before each test, the ore plate was moved, which ensured contact of the specimen with the abrasive surface in a new place. http://www.iaeme.com/IJMET/index.asp 1786 editor@iaeme.com
Yury Dukhnenko Figure 7. Schematic diagram for abrasion of metallic materials against rocks Work [41] describes tests for abrasive wear of agricultural equipment blades in a liquid- sand mass at a specially designed machine. Specimens of blades are placed in a mixture of water, sand and pebbles and rotate at a constant speed for 30 minutes. To identify wear resistance, the authors propose analysis and approximation of the cutting edge shape before and after the test by using an optical-analytical method. Work [42] deals with application of a shock-abrasive wear device designed for studying the effect of shock-abrasive wear on the lining of a ball mill. The device uses wear methods analyzed in papers [43]. The schematic diagram of the device is shown in Figure 8. Its operation principle is hammering a fixed specimen against the ore monolith. As a result of shock, the sample is subject to shock-abrasive wear. Figure 8. Device (a) to study shock-abrasive wear of materials and its schematic diagram (b) Similar devices for testing the effect of shock wear in metallic materials were described in [44-46]. The authors used sand as an abrasive material constantly pouring it onto a roller with increased hardness; simultaneously the tested material was hammered. 3. CONCLUSIONS Metallic materials tests for wear require a thorough approach and careful analysis of their operational conditions. Wear mechanism is determined by characteristics and properties of materials, which requires a balanced selection of the test method. Quite often, researchers have to develop a new technique based on typical working conditions of machines and equipment that makes it possible to adequately assess the wear rate of materials. Selection of only one http://www.iaeme.com/IJMET/index.asp 1787 editor@iaeme.com
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