Weir Minerals Division

6.0 - Wear Fundamentals

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6.0 - Wear Fundamentals

6.1 - Types of Wear

6.2 - Corrosion
6.3 - Mechanisms of Wear
6.4 - Wear Patterns
6.5 - Wear Testing
6.6 - Solutions to Wear
6.7 - Summary

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6.1 - Types of Wear

ƒ Erosion
ƒ Erosion is removal of material by impinging particles in a fluid stream
ƒ Particles transfer kinetic energy to surface
ƒ Specific contact pressure is high
ƒ High local stresses
ƒ Erosion is a function of impinging particle velocity
ƒ Wear = f (v)n
ƒ where:
ƒ n = 2 to 3

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6.1 - Types of Wear

ƒ Abrasion
ƒ Gouging is the removal of material by severe impacts
ƒ Large particles
ƒ High stress
ƒ Jaw and gyratory crushers
ƒ Grinding is loss of material from particles held between two surfaces
ƒ Small particles
ƒ High or low stress
ƒ Ball / rod mills

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6.1 - Types of wear

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6.2 - Corrosion

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6.3 - Mechanisms of Wear

Product: Erosion Abrasion
Direct Random
Sliding Bed Grinding
Part Impingement Impingement
Slurry Pump:
Impeller Vane - Leading Edge X
Impeller Vane - Pressure Side X
Impeller Vane - Suction Side X
Impeller - Expelling Vanes X X
Impeller Nose X X
Throatbush X X
Volute - Cutwater X
Volute - Wall X X
Frame Plate Liner X X X
Cover Plate Liner X X X
Frame Plate Liner Insert X X
Expeller X X
Shaft sleeve X
Cyclone:
Feed chamber X X X
Vortex finder X X
Spigot X
Gate Valve:
Gate X X
Body X X X

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6.3 - Mechanisms of Wear

1 SIDE_LINER
corr. wear rate (mm/h)

CASING-LINER
IMPELLER IM3
0.1

0.01

0.001
100 1000 10000

COMPONENT PARTS d85 (μm)

ƒThe different component parts in a slurry pump wear at different rates depending on
particle size, but generally follow the erosion model
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6.3 - Mechanisms of Wear

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6.3 - Mechanisms of Wear

ƒ Factors influencing wear behaviour

Contact
Erodent Substrate
Conditions
Particle size Velocity Physical properties
Particle shape Impingement angle Microstructure
Hardness Temperature - White irons
Yield strength pH - Elastomers
Fracture Particle density - Ceramics
Concentration

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6.3 - Mechanisms of Wear

Measuring Wear Rate

9

5 Q/Qbep=0.9
4 Q/Qbep=0.7
3 Q/Qbep=0.68
2
Q/Qbep=0.6

0
0 5 10 15 20 25

Cum. solids pumped (kT)

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6.3 - Mechanisms of Wear

ƒ Wear mechanisms - White Irons

ƒ Main mechanisms are ploughing,
cutting and fragmentation
ƒ Different phases may see
different mechanisms and wear
rates
ƒ In low stress erosion (small
particles, low velocity) matrix will
erode preferentially leaving
carbides unsupported
ƒ In high stress erosion (large
particles or velocity) carbides will
fracture or spall and may pull out

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6.3 - Mechanisms of Wear

ƒ Wear Mechanisms - Elastomers X 300

ƒ Main mechanisms are fatigue (low stress) and
cutting & tearing (high stress)
ƒ Cracks and/or tears propagate under repeated
particle impact
ƒ Cracks join allowing material removal
ƒ Elastomer wear is a function of physical
properties:
ƒ Resilience X 1500
ƒ Tear strength
ƒ UTS
ƒ Elongation
ƒ Size and shape of particle is important
ƒ Particle velocity (applied stress) is important
ƒ Subject to hysteresis failure in some conditions

X 3000

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6.3 - Mechanisms of Wear

ƒWear Mechanisms - Ceramics

ƒBrittle fracture
ƒFailure due to crack propagation
ƒSliding wear applications preferred
ƒWear resistance is a function of:
ƒ Particle shape
ƒ Ceramic fracture toughness
ƒ Particle impingement angle
ƒ Matrix hardness (Refrax,
Alanx)
ƒ Particle impact velocity

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6.3 - Mechanisms of Wear

ƒ Particle impingement velocity is always less than the free stream velocity

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6.3 - Mechanisms of Wear 0.7

Corr.wear rate (mm/h)

0.6
ƒEffect of Speed on Wear RE
0.5
ƒImpeller speed influences all HE
wear rates of all parts 0.4
STD
0.3
0.2
0.1
0.45 0
0.4 10 15 20 25
Corr. wear rate (mm/h)

0.35
0.3 Impeller tip speed (m/s)
0.25 RE
0.2 HE Impeller wear proportional to N3.5
0.15 STD Casing-liner wear proportional to N2.5
0.1 Erosion is main mechanism
0.05
0
10 15 20 25
Impeller tip speed (m/s) Side-liner wear proportional to N
Abrasion is main mechanism

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6.3 - Mechanisms of Wear

ƒEffect of Concentration on Wear
0.9
0.8
Inlet side-liner wear
Corr. wear rate (mm/h)

0.7
HE reaches a maximum at
0.6
STD Cv=0.3
0.5
0.4
0.3
0.2
0.1 0.7

0 0.6

Corr. wear rate (mm/h)

0 0.1 0.2 0.3 0.4
0.5
Cv
0.4
Impeller wear is at a 0.3
maximum at Cv=0.2
0.2
Particle interference STD
reduces wear above 0.1 HE
this concentration 0
0 0.05 0.1 0.15 0.2 0.25 0.3
Cv

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6.4 - Wear Patterns

ƒ “Horseshoe” vortex

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6.4 - Wear Patterns

ƒ “Horseshoe” vortex can interact
(reinforce) with trailing tip vortex from
impeller shroud to wear hole

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6.4 - Wear Patterns

ƒ Trailing tip
vortex from
impeller

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6.4 - Wear Patterns

6 L/s 11 L/s

8 L/s 16 L/s

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6.4 - Wear Patterns

ƒ Fine particles tend to follow the fluid flow streamlines

ƒ Large particles tend to travel in a straight line impacting the back

shroud.
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6.4 - Wear Patterns

Worn Impeller Profile

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6.4 - Wear Patterns

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6.4 - Wear Patterns

ƒ Fine particles wear can occur at any point of flow separation

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6.4 - Wear Patterns

ƒ “Edge” vortices

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6.4 - Wear Patterns

ƒ Large particle wear due only to impingement

(negligible wear due to vorticity)

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6.4 - Wear Patterns

ƒThroatbush
Wear is influenced by flow rate and impeller
design

0.12 0.7
0.6

Corr. wear rate (mm/h)

Corr. wear rate (mm/h)

0.1
0.5
0.08
0.4 d85=1000
0.06
0.3 d85=500
0.04 d85=1000 d85=150
0.2
0.02 d85=500 0.1
d85=150 0
0
0.4 0.6 0.8 1 0.4 0.6 0.8 1
Q/Qbep Q/Qbep

Throatbush with STD impeller Throatbush with HE impeller

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6.4 - Wear Patterns

ƒThroatbush

1
corr. wear rate (mm/h)

0.1

0.01 STD-WI
STD-Ru

0.001
100 1000 10000
d85 (μm)
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6.4 – Wear Patterns

Wear on throatbush can be skewed by

uneven pressure distribution in volute
which is dependent on flow relative to
Qbep
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6.4 - Wear Patterns

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6.4 - Wear Patterns

HE 3000h
HE (LF) 3000h
Q/Qbep=0.83; d85=270μm
Q/Qbep=0.4; d85=650μm
EP 3000h
RE (LF) 2100h

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6.4 - Wear Patterns

Corr. w ear rate (mm/kT) 1.4
1.2
STD
1
0.8 HE
0.6
0.4
0.2
0
0 500 1000 1500
d85 (μm)

ƒParticle size is a major determinate of casing-

liner wear rate
ƒWear higher with HE impeller

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6.4 - Wear Patterns

ƒ Effect of Particle Size on Wear Patterns

10 micron alumina

6mm gravel

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6.4 - Wear Patterns

ƒ Other wear patterns - Cavitation

New photos required

Cavitation due to Cavitation at vane inlet of dredge

discharge recirculation pump impeller operating on very
near vane tip high suction lift
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6.4 - Wear Patterns

1
corr. wear rate (mm/h)

0.1

STD-WI
0.01
STD-Ru1
STD-Ru2
0.001
100 1000 10000
d85 (μm)
Casing Liner Wear - White Iron Vs Natural Rubber
RU1 = < 6/4 size
RU2 = > 8/6 size
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6.4 - Wear Patterns

Other wear patterns - Hysteresis

Elastomer
depolymerisation due to
high frequency pressure
pulse from impeller
“pump-out” vanes

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6.5 - Wear Testing

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6.5 - Wear Testing

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6.5 - Wear Testing

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6.6 - Solutions to Wear

Example
•Approximation of impeller vane
leading edge impact velocity
established for 100HRM, 6/4AH &
8/6AH.
•Wear rate factor calculated for
each option based upon the square
of the impact velocity ratio of
proposed impeller against
100HRM.

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6.6 - Solutions to Wear

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6.6 - Solutions to Wear

Selection to Minimise Wear

ƒ d85<300μm
ƒ HE pump with elastomer liners and metal or elastomer impeller
ƒ good efficiency
ƒ 300μm<d85<1000μm
ƒ STD for 0.5<Qbep<1.1
ƒ RE for Qbep<0.5
ƒ metal impellers
ƒ all elastomer liners d85<600μm up to 6/4
ƒ metal side-liners d85>600μm
ƒ elastomer casing liners for 8/6 and larger

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6.6 - Solutions to Wear

Wear Life Uncertainty

ƒ Wear life depends on

ƒ local wear rate
ƒ wear pattern (how wear rate is distributed)
ƒ Variable nature of wear life caused by
ƒ erratic nature of erosion process
ƒ variation in slurry and plant process
ƒ Problems caused by wear life uncertainty
ƒ timing of scheduled maintenance
ƒ premature replacement of parts
ƒ plant down-time due to premature failure
ƒ inadequate reference to wear life changes following improvement projects
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6.6 - Solutions to Wear

ƒUncertainty analysis
ƒprobability distribution of time to reach
failure Mean
life
ƒGaussian distribution is most used for
erosion/abrasion
ƒuse functional failure (head

Frequency of failure
developed, diminished flow rate, Useful
parts holed, etc.) life

ƒuse coefficient of variance as a

measure of relative uncertainty (COV) =
standard deviation/mean
ƒs=(1/n*Σ(xi-x)2)0.5

Age at failure

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6.6 - Solutions to Wear

ƒ Localised wear to be solved through hydraulic design by:

ƒ eliminating or modifying flow pattern
ƒ spreading wear over a larger area

ƒ Global wear to be solved through material selection or changing

the wear characteristics of the substrate

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6.7 - Discussion

ƒ What are the primary wear mechanisms?

ƒ What effect does corrosion have?
ƒ What is the major cause of wear on the leading edge of an impeller vane?
ƒ What is the major wear mechanism on a shaft sleeve?
ƒ What are the three major factors influencing wear?
ƒ What causes Hysteresis?
ƒ What is the cause of cavitation?
ƒ What can you do to minimise wear?

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