100cm by 100cm Poster Template

1
Effect of Impingement Angle and Erodent
Temperature on Erosion Wear Behavior of Bamboo
Fiber Reinforced Epoxy Composites Sandhyarani
Biswas1 Alok Satapathy1 Amar Patnaik2
Mechanical Engineering Department 1National
Institute of Technology, Rourkela-769008, India
2National Institute of Technology,
Hamirpur-177005, India
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ABSTACT
For a composite material, its surface damage by
solid particle erosion depends on many factors.
One of the most important characteristics of
erosion is the variation of erosion rate with
impingement angle. Determining the effect of the
impingement angle on erosion is the most
sensitive way of studying the mechanism of
erosion. The erosion rate is also greatly
affected by the erodent temperature. In the
present work a series of systematic erosion tests
were carried out to investigate the influence of
impingement angle and erodent temperature on
erosion mechanisms of bamboo fiber reinforced
epoxy composites using an erosion test rig.
Bamboo fiber reinforced epoxy composites are
fabricated using red mud, copper slag, Al2O3 and
SiC particles as filler materials. The erosion
rates of these composites have been evaluated at
different impingement angles (15-90) and at
different erodent temperatures (30-60C) and the
conclusions drawn from the above investigation
are discussed. Keywards Solid particle erosion
Impingement angle Erodent temperature Bamboo
fiber Filler
In the present study, dry silica sand of
different particle sizes (300µm, 450µm and 600µm)
are used as erodent. The samples are cleaned in
acetone, dried and weighed to an accuracy of 0.1
mg before and after the erosion trials using a
precision electronic balance. The weight loss is
recorded for subsequent calculation of erosion
rate. The ratio of the weight loss to the weight
of the eroding particles causing the loss is then
computed as a dimensionless incremental erosion
rate. The process is repeated till the erosion
rate attains a constant value called steady state
erosion rate.
It is seen, in this figure, that for all the
composite samples, the erosion rates remain
almost unaffected by the change in erodent
temperature from ambient to 400C.
EXPERIMENTAL DETAILS Composite Fabrication
Figure 3. Effect of erodent temperature on the
erosion wear rate of the composites
The fabrication of the various composite
materials is carried out through the hand lay-up
technique. Roving bi-directional bamboo mats are
reinforced in particulate filled epoxy (LY 556)
composites. The epoxy resin and the hardener
(HY951) are supplied by Ciba Geigy India Ltd.
Four different fillers such as copper slag, red
mud, alumina and Silicon carbide are used in this
study. Copper slag collected from the plant site
of Hindustan Copper Limited, at Ghatsila, India.
Red mud collected from NALCO aluminium refinery
at Damanjodi, India. Aluminium oxide and silicon
carbide powders of similar size range are
obtained from NICE Ltd India. All the four
fillers are sieved to a particle size range of
80-100 µm. The average thickness of bamboo fibers
is about 1.5 mm. The extracted fibers are dried
in an oven at 105C for 72 hours to remove
moisture. Each ply of bamboo-fiber is of
dimension 200 200 mm2. A stainless steel mould
having dimensions of 210 210 40 mm3 is used.
The low temperature curing epoxy resin and
corresponding hardener are mixed in a ratio of
101 by weight as recommended. The composites
prepared for this study are designated as Z1, Z2,
Z3, Z4, Z5, Z6, Z7, Z8 and Z9 respectively. The
detailed compositions along with the designation
are presented in Table 1. The cast of each
composite is cured under a load of about 50 kg
for 24 hours before it removed from the mould.
Then this cast is post cured in the air for
another 24 hours after removing out of the mould.
Specimens of suitable dimension are cut using a
diamond cutter for erosion testing. Utmost care
has been taken to maintain uniformity and
homogeneity of the composite. Table 1.
Designation and detailed composition of the
composites
CONCLUSIONS

• This study on the erosion behaviour of
  particulated filled epoxy composites with bamboo
  reinforcement leads to the following conclusions
• Hybrid composites suitable for applications in
  highly erosive environments can be prepared by
  reinforcement of bamboo fibers and filling of
  micro-sized fillers such as alumina, SiC, red mud
  and copper slag particles in epoxy resin.
• Study of influence of impingement angle on
  erosion rate of the composites filled with
  different weight percentage of particulates
  reveal their semi-ductile nature with respect to
  erosion wear. The result shows the peak erosion
  taking place at an impingement angle of 600 for
  the unfilled as well as the red mud (RM) and
  alumina filled bamboo-epoxy composites, whereas
  composite samples filled with copper slag, the
  maximum erosion rate is recorded at an
  impingement angle of 450 under similar
  experimental conditions. However, composite
  samples filled with SiC, the maximum erosion rate
  is recorded at an impingement angle of 750.This
  clearly indicates that these composites respond
  to solid particle impact neither in a purely
  ductile nor in a purely brittle manner. This
  behaviour can be termed as semi-ductile in
  nature. The erosion rate is also greatly affected
  by the erodent temperature.
• For all the composite samples, the erosion rates
  remain almost unaffected by the change in erodent
  temperature from ambient to 400C.
• Possible use of these composites in components
  such as pipes carrying coal dust, helicopter fan
  blades, industrial fans, desert structures, low
  cost housing, etc. is recommended. In future,
  this study can be extended to new hybrid
  composites using other potential fillers and the
  resulting experimental findings can be similarly
  analyzed.

Figure 1. Schematic diagram of an erosion test rig
RESULT AND DISCUSSION Steady state erosion
(Effect of impingement angle of erosion rate)
The variations of steady-state erosion rates of
bamboo-epoxy and glass-epoxy composites filled
with red mud particulates with the angle of
impingement are presented in Fig. 2. The erosion
behavior of materials is broadly classi?ed in the
literature as ductile and brittle depending on
the variation of erosion rate with impact angle.
Ductile behavior is characterized by maximum
erosion at low impact angles in the range o f
10300. On the other hand, if maximum erosion
occurs at a 900, then the behavior is brittle.
However, reinforced composites have been found to
exhibit semi-ductile behavior with maximum
erosion rate at intermediate angles typically in
the range of 45600 1. In the present study,
the variation of erosion wear rate of the
composites with impingement angle is studied by
conducting experiments under specified operating
conditions. The result shows the peak erosion
taking place at an impingement angle of 600 for
the unfilled as well as the red mud (RM) and
alumina filled bamboo-epoxy composites, whereas
composite samples filled with copper slag, the
maximum erosion rate is recorded at an
impingement angle of 450 under similar
experimental conditions. However, composite
samples filled with SiC, the maximum erosion rate
is recorded at an impingement angle of 750.This
clearly indicates that these composites respond
to solid particle impact neither in a purely
ductile nor in a purely brittle manner. This
behaviour can be termed as semi-ductile in nature
which is in agreement with the trend observed by
previous investigators 1.
Designation Composition
Z1 Epoxy 50wt bamboo fiber
Z2 Epoxy 50wt bamboo fiber 10wt Red mud
Z3 Epoxy 50wt bamboo fiber 20wt Red mud
Z4 Epoxy 50wt bamboo fiber 10wt Copper slag
Z5 Epoxy 50wt bamboo fiber 20wt Copper slag
Z6 Epoxy 50wt bamboo fiber 10wt Alumina
Z7 Epoxy 50wt bamboo fiber 20wt Alumina
Z8 Epoxy 50wt bamboo fiber 10wt SiC
Z9 Epoxy 50wt bamboo fiber 20wt SiC
REFERENCES

1. Ruff A W, Ives L K. Measurement of solid particle
   velocity in erosive wear. Wear 1975 35 (1)
   195-199.

List of Materials used in the present work
Matrix EPOXY Fiber Natural Fiber
Bamboo Particulate Fillers Red Mud Copper
Slag Alumina Silicon Carbide
Erosion test apparatus
The solid particle erosion experiments are
carried out as per ASTM G76 using a standard
erosion test rig. The test rig consists of an air
compressor, an air drying unit, a conveyor
belt-type particle feeder and an air particle
mixing and accelerating chamber. The dried and
compressed air is then mixed with the silica sand
which is fed constantly by a conveyor belt feeder
into the mixing chamber and then accelerated by
passing the mixture through a convergent brass
nozzle of 3 mm internal diameter. The set up is
capable of creating reproducible erosive
situations for assessing erosion wear resistance
of the composite samples. The erodent particles
impact the specimen which can be held at
different angles with respect to the direction of
erodent flow. The apparatus is equipped with a
heater which can regulate and maintain the
erodent temperature at any pre-determined fixed
value during an erosion trial.
Figure 2 . Effect of impingement angle on the
erosion wear rate of the composites
Effect of erodent temperature on erosion rate
Similarly, the variation of erosion rate of
unfilled and red mud filled composites with
erodent temperature is shown in Fig. 3. This
figure also presents the erosion rate of all the
particulate filled composites with bamboo
reinforcement for different erodent temperatures.
Erosion trials are conducted at seven different
temperatures under normal impact condition.