New wear test devices narrow thegap between research and practiceProject Manager Kati ValtonenTampere University of TechnologyDepartment of Materials ScienceTampere Wear Center

FIMECC DEMAPP Program Final Seminar30.9.2014, Espoo

Wear resistantmaterials and

solutions“Towards

comprehensivecontrol of wear”

Developmentof new wear

resistantmaterials and

characterizationof their

microstructureand properties Development

and applicationof new wear

testingtechniques and

test facilities

Modeling of thewear processeswith increasing

complexity

Analyzing andcombining the

characterization,wear testing,and modeling

results

Development of application oriented wearresearch infrastructure

Challenge:Extreme diversityand complexity ofwear phenomena

Development of application oriented wearresearch infrastructure

Challenge:Extreme diversityand complexity ofwear phenomena

Approach:Combining of

materialscharacterization,wear testing, and

modeling

Wear resistantmaterials and

solutions“Towards

comprehensivecontrol of wear”

Development ofnew wearresistant

materials andcharacterization

of theirmicrostructureand properties

Development andapplication of

new wear testingtechniques and

test facilities

Modeling of thewear processeswith increasing

complexity

Analyzing andcombining the

characterization,wear testing, andmodeling results

Development of application oriented wearresearch infrastructure

Challenge:Extreme diversityand complexity ofwear phenomena

Approach:Combining of

materialscharacterization,wear testing, and

modeling

Progress:Developmentof novel wear

testingmethods and

facilities

Laboratory scale dual pivoted jaw crusherfor studying the mechanisms of abrasivewear during mineral crushingHigh speed slurry-pot type erosion weartester for testing the wear resistant materialsfor industrial solutionsImpeller-tumbler testing device to determinethe effects of impact-abrasion wear in mineralhandling and transportHigh velocity particle impactor for thestudies of the mechanisms of impact erosiondamage and for the numerical model andsimulation verifications

Dual pivoted jaw crusherA novel reduced-size laboratory scalejaw crusher for studying the mechanismsof abrasive wear during mineral crushing– replaces/complements the standardized test

ASTM G 81-83, which has a fixed openingangle and fixed movement between the jaws

– can be used to determine the materialproperties beneficial to wear resistance at anycombination of compressive and slidingabrasion

Key design features:– control of jaw movement without changing the

test geometry, enabling accurate control of thecompression-sliding ratio.

– versatile instrumentation for monitoring thewear processes, including piezoelectric forcesensors, high speed video systems, etc.

Dual pivoted jaw crusher

Compressioncompression/sliding ratio 10:1

Slidingcompression/sliding ratio 1:8

High-speed slurry-pot type erosion testerTesting of wear resistant materialsin high stress erosive or abrasivewear conditions

– dredging pumps– mining applications– loader buckets

Testing of mineral abrasiveness ina slurry or in dry conditionsKey design features:– high rotation speed: up to 2000

rpm (20 m/s in the sample tip)– large abrasive size: 0-10 mm– suitable for testing of metal bars or

plates, thick and thin coatings,elastomers, and hybrid materials

– possibility to edge protection– flow conditions vary in 4 sample

levels ® requires sample rotation

Impeller-Tumbler Impact-Abrasive Wear TesterSimulates wear in mineral handling applications, such as earth movingmachinery and impactor plants.During the test, an impeller with three samples rotates inside a rotatingtumbler filled with gravel.– Impeller rotating speed up to 700 rpm,

tumbler rotating speed up to 120 rpm– Variables: sample angle, gravel size

distribution, type, and amount– One sample is the reference ® changes

in mineral composition controllable

Impeller-tumbler

Abrasion TestingScratch testing with natural rockintender to produce simplifiedwear tests with controlled loadsSharp asperities are createdduring the test by fracturing ofthe rockLimitation: every tip is different

Crushing pin-on-disc simulatesmineral crushing and handlingapplicationsContact mode, high loads, largeabrasive size, abrasive type, andthe comminution of the abrasiveform the basis for the testsVariables: disc, abrasive, load

High Velocity Particle Impactor (HVPI)Developed for the model verification and to identify the basic mechanismsinfluencing the impact wear and failure behavior of materialsKey design features:– various angles and impact energies; projectile speed: 30…200 m/s– suitable for various materials: metals, coatings, elastomers, hybrids, ...– projectiles: metallic or ceramic ball bearing balls, cylinders, bullets, and rocks– video recording: high speed camera NAC MEMRECAM up to 80 000 fps or

LaVision StrainMaster 3D DIC systems (high and low rate)

Trap wall

Targetassembly

Speedmeasurement

device Smooth bore

Pressurecontrol

Pressurizedair tank

Specimen

Experimental research plays a key role insolving wear problems

The wear test results have been utilized in thesteel development work at Ruukki Metals.– enhanced understanding of the wear phenomena

was the enabling factor in the improvement of thewear resistance of the new steels.

– results have also been used to help customers toselect the best materials for their applications.

Wide range of wear resistant steels and othernovel materials developed in the project werewear tested as prospective materials forMetso’s crushing and grinding systems.The developed dual pivoted jaw crusher hasproven a valuable tool for better understandingof the combined effects of different crushingparameters and mineral properties.– will be used for example in the process planning

and development of process optimization tools atMetso.

Results through Collaboration

14

Contact

Kati ValtonenTampere University of TechnologyDepartment of Materials ScienceTampere Wear Center

http://www.tut.fi/twc/en

FIMECC DEMAPP programhttp://www.fimecc.com/content/demapp-demanding-applications-program

DEMAPP Program - Final Seminar 30.9.2014