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Preprint 12-013
A SUCCESSFULLY SERVICE TESTED HARD IRON WITH SUPERIOR ABRASION AND CORROSION RESISTANCE IS
AVAILABLE FOR THE MINERAL PROCESSING INDUSTRY.
G. A. Calboreanu, ARW & Sons Inc, Denver, CO
ABSTRACT
respectively 13-m versus 5-m the denuded zone width of proeutectic chromium carbide.
Max10
25 Cr%
Hard Iron
Location
Matrix
Eut. Carbide
Interface
Matrix
Eut. Carbide
Interface
EDS analyses
% Cr
% Fe
15.9
84.0
62.9
37.0
68.28
31.72
15.5
54.0
13.6
Phosphoric Acid
Most of time phosphate rocks have high amounts of quartz, ferric
oxide and harmful corrosive erosive contaminants. In such
operations Max10 is very much needed.
pH [OH ] = 14 pH [H ]
-
(1a)
(1b)
The base solution was 60% phosphoric acid at 150 F (66 C).
In such solution Max10 is completely inert;
Through stoichiometric calculation the ferric chloride addition
provided 100 PPM ionic chloride;
Testing time 192 hours while testing results are shown in
Table 2.
Photos 9, 10 and 11. Viewing the pin-on-disk wear apparatus and the
arm holding the pyramidal shaped Rockwell C testing diamond
indenter see Arrow N.
Corrosion rate
[MPY]
29.92
5.36
14.57
After 72 testing hours the corrosion rate was 29.92 MPY however
after additional 120 testing hours the corrosion rate dropped to 5.36
MPY which proves that Max10 passivated. The average corrosion rate
is 14.57 MPY which is ranked very good.
275 m
K
Photo 7.
Photo 8.
Values
80
2 hours
0
72 F
15.875 mm
49.848 mm
478.54 m
1,063 g or 10.425 Newton
0.20 0.12 m
WEAR TESTING
Photo 9 shows the pin-on-disk wear testing apparatus used to
evaluate the wear resistance of Max10. Arrow M points to the 1- inch
x 1- inch x 0.25- inch thick test sample pinned on the 80 RPM rotating
table. During testing the contact point between the sample and the
indenter is constantly flushed with water.
Usually the pin-on-disk wear test is accomplished with a 0.25-inch
diameter alumina ball which progressively breaks into the sample
surface producing the wear track seen in Figure 4. However an
alumina ball wouldnt penetrate into hard irons therefore it was
replaced with a diamond indenter.
Figure 5 and Photo 12. Schematic view of the wear forces acting on
the Max10 sample and the cyclic material pile up in the wear groove.
When compressive stresses are unable to push the front pile the
diamond indenter jumps over the pile developing cyclic material pile
ups see Arrow O in Photo 12.
Table 4 shows the wear rate of Max10 and 25% Cr hard iron soft
annealed, machined and hardened. Despite the 415 HBN hardness of
Max10 versus 620 HBN hardness of 25% Cr their wear rates are
Photo 14. SEM view of cup con ductile features found on the
fractured tensile specimen surface.
The hardness range of Max10 is 400 460 HBN and was tested
with New Age Shear Pin and 3,000 kgf Brinell apparatus.
Fracture Toughness
The fracture toughness established by KIVM per ASTM E1304 is a
relative slow advancing steady crack initiated at the tip of the very
sharp Chevron point and propagates as seen with Arrow R in Photo
16.
KIVM = x PM / B x(W)
*
Elongation
[%]
1.00
PM
B
W
W/B
Max10 likewise all hard irons have equal tensile and yield
strength. Although the specimen fractured without necking Max10 had
1.00% measured elongation. This beneficial result is somewhere
unique because hard irons are without any elongation. The cup con
ductile features on the specimen fractured surface are formed under
1/2
(2)
Photos 18 and 19. The pump case and impeller failed in less than
four months when poured with a different material then Max10.
SERVICE PERFORMANCE
Pumps
The severe corrosion erosion conditions of a 24 / 7 operation
damaged rapidly the pump components of all previously used
materials. Photo 18 shows a severely damaged pump case poured
from a different material then Max10. Arrow S points to the damaging
spiral wear pattern which in a few locations broke through the pump
case volute. Arrow T in Photo 19 shows the remnants of an
impeller.
CONCLUDING REMARKS
1.
3.
ASTM G99 Standard test method for wear testing with pin-ondisk apparatus.
2.
3.
4.
5.
6.
and
definitions
for