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2013-Petrica-etal-Abrasive Wear Mechanisms and Their Relation To Roc...
2013-Petrica-etal-Abrasive Wear Mechanisms and Their Relation To Roc...
2013-Petrica-etal-Abrasive Wear Mechanisms and Their Relation To Roc...
Wear
journal homepage: www.elsevier.com/locate/wear
art ic l e i nf o a b s t r a c t
Article history: Wear caused by abrasion is the predominant factor in mining industry. Abrasive wear is a rapid and
Received 5 July 2013 severe process due to the contact between abrasives and solid material surfaces. This type of wear is
Received in revised form usually classified into two categories: (i) 2-body abrasive wear and (ii) 3-body abrasive wear according to
10 October 2013
the type of contact that occurs between the abrasives and the material. The tribological system formed in
Accepted 11 October 2013
mining environment embraces both abrasive wear categories. The focus of this paper is to bring in
Available online 23 October 2013
detailed focus the 2-body and 3-body wear behaviour based on correlations which point out some
Keywords: physical and mechanical rock properties having a significant influence. The study was based on three
Rock types different rock types wearing a typical martensitic steel 42CrMo4 (DIN 1.7225) under 2-body conditions
Abrasion
using a Cycling Impact Abrasion Test (CIAT) and 3-body conditions using a Slurry Steel Wheel Abrasion
Wear
Test (SSWAT). Results showed that tested rocks perform totally different when the testing conditions are
Mining
Tribology changed. Furthermore, the specific wear energy under 3-body conditions was calculated in order to gain
understanding regarding energy needed to produce wear.
& 2013 Elsevier B.V. All rights reserved.
1. Introduction is lower than that under 2-body conditions mainly due to this
change of interaction between the particles and the surface
Machinery that performs in dusty environments such as [10,12]. Due to particle impact under 2-body conditions, cutting
construction or mining industry is exposed to direct contact with and ploughing mechanisms are dominant. Anyhow, an important
abrasives which enter and become entrapped between the aspect in describing abrasive wear that occurs under 2-body or
components, resulting in abrasive wear. Among all the wear 3-body conditions is the characterisation of the abrasive parti-
problems that occur in these industries, 50% are generated cles. Therefore it is of high importance to address the abrasive
by abrasive wear [1–3]. Some models have been used in the characteristics of rocks. Properties such as brittleness or porosity
literature to describe 2-body abrasion which arises due to the have definitely a huge impact on the characterisation of the wear
impact of abrasives to the surface concluding in sliding/scratch- behaviour. In the literature 2-body and 3-body abrasive wear
ing or embedment of the particles on the wearing surface [4–7]. contact has been studied in detail in recent years; however only a
However, when abrasive wear is caused by free moveable few have concentrated their study in analysing the abrasives that
particles between two surfaces these models do not suffice. generate wear [13–15]. Woldman et al. [16] referred to the huge
2-body abrasive wear phenomena have been more extensively importance of shape and size of the particles describing the wear
studied, although 3-body abrasive wear is much more present in behaviour of materials. The particle size effect on abrasion was
many industrial applications. A range of wear rates have also reported elsewhere [17–19]. However, the mineralogical
been reported for the 3-body wear conditions which depend compositions of the abrasives, their origins, and how the com-
not only on the tested material but also on the testing method position might affect the wear behaviour were not deeply under-
itself [8–11]. stood. Few studies were carried out to find correlations that
It has become clear that the manner in which particles might exist between the abrasive wear and the mineralogical
interact with the surface strongly influences the wear behaviour. composition of the abrasives involved in the process. In a
Particles might roll and/or slide over the surface. According to previous study [20] it was shown in detail that under variation
this assumption the wear mechanisms resulted might also differ. of abrasives the generated wear mechanisms in 2-body contact
It is generally shown that under 3-body conditions the wear rate differ. This fact clearly points out the dependence between
abrasives properties and generated wear.
This paper focuses on establishing correlations which enable a
n
Corresponding author. Tel.: þ 43 2622 81600 306; fax: þ 43 2622 81600 99. deeper fundamental understanding of how the wear mechanisms
E-mail address: petrica@ac2t.at (M. Petrica). are generated, considering abrasive properties. Nevertheless,
0043-1648/$ - see front matter & 2013 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.wear.2013.10.005
M. Petrica et al. / Wear 308 (2013) 86–94 87
2. Experimental details
2.2.2. Cyclic Impact Abrasion Test (CIAT) – 2-body impact/abrasive Fig. 1. Macro-images of the used rock types: (a) granite; (b) meta-sandstone; and
wear (c) sandstone.
Table 1
Summary of mineralogical composition of the investigated rocks.
Fig. 2. View of the Slurry Steel Wheel Abrasion Test (SSWAT): (a) testing device; (b) testing chamber; and (c) slurry feeding device.
Fig. 4. Macrographs of the abrasives used in the 3-body abrasion test: (a) granite; (b) meta-sandstone; (c) sandstone; and (d) quartz.
Fig. 9. 3D images with the worn surface of the martensite after SSWAT with different abrasives: (a) granite; (b) meta-sandstone, (c) sandstone; and (d) quartz.
Fig. 10. SEM micrographs of the worn surfaces after SSWAT with different abrasives: (a) granite; (b) meta-sandstone; (c) sandstone; and (d) quartz.
porosity as in sandstone is therefore indicative of lower rock that describes the wear behaviour under 2-body conditions, it can
brittleness. In general it is reflected in the compressive and tensile be concluded that rocks with high UCS as in the case of granite
strength of a rock. Considering UCS as a mechanical rock property which produces mechanisms such as cutting or ploughing, an
92 M. Petrica et al. / Wear 308 (2013) 86–94
Fig. 15. Correlations among wear rate, quartz content and specific wear energy
under 3-body conditions.
sandstone followed by quartz, whereas meta-sandstone and gran-
ite exhibit the lowest friction power during testing. This fact
indicates that measured friction power is in good correlation with
the detected wear rates, where high friction power corresponds to
increased wear rates. The calculated specific wear energy using conditions can be summarised. On the other hand, sandstone has
different abrasives is given in Fig. 14. The highest value of specific the highest quartz equivalent and produces the highest wear rate of
wear energy is calculated for granite to be 2000 J/mm³ followed all abrasives tested. Having a look on the specific wear energy that
by meta-sandstone at 1000 J/mm³. Sandstone and quartz refer- shows a low value, this makes sandstone a highly abrasive rock in
ence exhibit the lowest specific wear energy values. This means the case of 3-body conditions. Porosity is another important rock
that for removing an equivalent volume of material, granite needs property which influences the degree of cementation. A high
6–8 times more specific wear energy compared to quartz and porosity indicates a low level of cementation which can express
sandstone, and 2 times more compared to meta-sandstone (see the susceptibility of a rock to a breaking tendency or brittle
Fig. 14). Furthermore, it can be concluded that the specific wear cracking. In general porosity is reflected in the UCS (see Table 2)
energy calculated for each type of abrasive gives information which is the most relevant property in the case of 2-body impact/
regarding their potential producing wear. The higher the specific abrasion conditions. In a previous study [20] the relation between
wear energy, the lower the abrasivity of that rock. wear and the UCS value was clearly shown. Furthermore, a high UCS
value (as in the case of granite) correlated with low particle
3.5. Influence of rock properties on the wear rates under 2-body and breakage index (P.B.I). This correlation explained the interdepen-
3-body conditions dence between the rock brittleness, porosity and the produced
wear. Therefore, a high UCS value shows that (i) the brittleness of
A classification of rocks regarding their abrasivity is possible the rock is high, (ii) the porosity is low, (iii) the particle breakage
with respect to a well defined environment. Wear phenomena index is low and (iv) the generated wear by impact is high. As
occurring under 3-body conditions in real field conditions are shown in Fig. 12 the highest wear rate was generated by granite due
typical for specific mining systems. There the rocks are smashed to the highest UCS value, the highest brittleness at the lowest
under high contact pressure and further the small abrasive porosity and the lowest P.B.I. Comparing wear results obtained
particles get trapped between different body parts of components. under 3-body and 2-body conditions (see Figs. 8 and 12) an
Also 2-body impact/abrasion conditions are well known environ- opposite trend can be observed which is mainly based on the
ments in mining, where components get in direct contact with the significance of rock properties interacting with wearing surfaces.
rocks. Here the wear is mainly produced by the strong impact
between the rock and the wearing surface of the tool or compo-
nent. In order to estimate how severely these types of wear are 4. Conclusions
formed depending on the abrasive environments, selected rock
properties influencing wear under selected conditions have to be Within this study done on the characterisation of abrasive wear
considered. The content of hard minerals in rocks (e.g. quartz) mechanisms and their influence on selected mechanical rock
plays an important role in the case of 3-body conditions. As properties, the following main conclusions can be drawn:
presented in Table 1, quartz and feldspar are the main mineral
components in the used rocks. Quartz is well known to be a The difference in abrasivity and wear mechanisms, associated
mineral with high hardness of 1000–1200 HV ( 7 on the Mohs with the investigated rocks, between 2-body and 3-body
hardness scale) [34]. To consider all abrasive minerals within the testing conditions has been shown and established;
composition of the rocks, the equivalent quartz content (Eq) was opposite wear trends have been found when 2-body and 3-
determined. Some studies were done to find dependence between body conditions are compared which have a major influence on
abrasive wear and the content of minerals from the abrasives different rock properties in each case;
[35–37]. Plinninger et al. [38] refer to a correlation described as the content of hard minerals within rock composition is the
low level abrasive wear when the minerals involved are softer dominant factor in the expected abrasivity of certain rock types
than the tool and as high level abrasive wear when the content of in the case of 3-body wear conditions;
minerals harder than the tool exceeds 20%. This theory is in good the brittleness of the rock defined by the ratio of uniaxial
agreement with the results presented in this paper. Fig. 15 shows compressive strength (UCS) to BTS is the determinant factor in
the correlation between the equivalent quartz content and the wear the expected abrasivity of certain rock types in the case of
rate under 3-body conditions. As can be seen granite has the lowest 2-body wear conditions;
quartz equivalent leading to the lowest wear rate and furthermore the calculated specific wear energy related to each type of rock
the specific wear energy needed for granite to produce wear is high. is directly correlated with the abrasive behaviour of the
Based on this low abrasivity for granite in the case of 3-body investigated rocks.
94 M. Petrica et al. / Wear 308 (2013) 86–94
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This work was funded by the “Austrian Comet-Program”
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