Tampere Wear CenterResearch Equipment

Kati ValtonenProject Manager

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

2Tampere University of Technology (TUT) – At the Leading Edge

• Established in 1965• Started operating in the form of a foundation in 2010• 10,400 students (2010)• Collaborates with 200 universities around the world

Department of Materials Science

• Founded 1969• Personnel about 150, 9 professors• Turnover about 10 M€ (2011)• Head of the Department: Veli-Tapani Kuokkala• Laboratories

– Materials Science– Materials Characterization– Surface Engineering– Plastics and Elastomer Technology– Ceramic Materials– Metals Technology– Fibre Materials Science– Paper Converting and Packaging– Laser Application Laboratory– Tampere Wear Center

Tampere Wear Center - TWC

Research equipment• Wear equipment: Pin-on-disk/Ball-on-disk,

Crushing pin-on-disk, Uniaxial crusher, Dual pivoted jaw crusher, Impeller-tumbler, Erosion tester, High-speed slurry-pot type erosion tester, Cavitation erosion tester, High velocity particle impactor, Ball-on-block, Hammer mill, High-speed sliding test rig, Single disc refiner, Pin-on-plate, Biomaterial crusher, Block-on-ring, Rubber wheel abrasion testers, etc.

• Electron microscopes (UHR FEG-SEM, TEM)• Hopkinson Split Bar• Digital image correlation system• Mechanical testing• Hardness testing• Thermal spraying• Other equipment

CETR UMT-2 Pin/Ball-on-diskCommercial Pin-on-disk / Ball-on-disk equipment; fulfills ASTM G99 –95a standard

Elevated-Temperature Chamber:• Temperature: -20-350°C• Revolve disk speed: 0.1 - 1000 rpm• Max. disk size: 70 mm• Standard specimens:

•Pins: Diameter of 6.35 and 10 mm•Balls: Diameter of 6.35 and 9.5 mm

• Humidity/Gases Chamber (no controls)• Possibility to use lubricants• Humidity control: 5-95%RH

High-Temperature Chamber:• Temperature up to 1000°C• Revolve disk speed: 0.1 - 1000 rpm• Max. disc size: 50 mm• Standard specimens:

•Pins: Diameter of 6.35 and 10 mm•Balls: Diameter of 6.35 and 9.5 mm

Crushing Pin-on-disk• Pin is repeatedly pressed against

the gravel bed and the disk with a pneumatic cylinder (200-500N)

• Pin does not come into direct contact with the disk at any time ®wear of the components due to abrasive ploughing and cutting on the pin and disk surfaces

• During the test, the abrasive size decreases at different rates, depending on the pin-disk combination.

• Simulates cone or jaw crusher

Disk:* Diameter of 160 mm* Thickness of 2-155 mm* Rotating velocity control

Specimen:* Diameter of 36 mm* Height of 35 mm* Flat area 1000 mm²

Uniaxial Crusher• The equipment crushes the abrasive uniaxially

between two specimens with a high pressure• Controlled amount of the abrasive• Simulates a mineral crusher

• Specimen: area of 1000mm², height of 35 mm and diameter of 36 mm

• Impacts with the hydraulic cylinder:• 6 bar (max) 86 kN• 5 bar 69 kN• 4 bar 53 kN• 3 bar 39 kN• 2 bar 23 kN

Dual pivoted jaw crusher• A novel reduced-size laboratory scale

jaw crusher for studying the mechanisms of abrasive wear during mineral crushing

– Replaces/complements the standardized test ASTM G 81-83

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

the test geometry, enabling accurate control of the compression-sliding ratio

– versatile instrumentation for monitoring the wear processes, including piezoelectric force sensors, high speed video systems, etc.

• Specimen– small jaw plate size 75*25*10 mm

concentrates the abrasion to a small area– abrasive particle size 6-14

Impeller-tumbler impact-abrasive wear tester• During the test, an impeller rotates inside a rotating tumbler filled with gravel.

Three samples are attached to the impeller. As the impeller and the tumbler rotate, gravel moves inside the tumbler and impacts on the specimens.

• Impeller rotating speed up to 700 rpm• Tumbler rotating speed up to 120 rpm• Specimen: 75*25*10 mm• Variables: gravel size distribution, type, and amount

High-speed slurry-pot type erosion tester

• Testing of wear resistant materials for mining and dredging pumps

• Testing of mineral abrasivity in slurry or in dry conditions

• Specimens:– Profile: round or square– Thickness 18.5 mm / 15 mm– Length 65.5 mm from shaft

• Slurry:– Up to 10 l of water– Abrasive size 0-10 mm– Selectable amount of abrasive

• Shaft:– Diameter 60 mm– Rotation speed up to 2000 rpm– Specimen tip speed up to 20 m/s

Erosion testerWear testing of materials and coatings at room temperature with centrifugal accelerator

• Impact angle: 15°, 30°, 45°, 60°, or 90°• Impact velocity: 0-80 m/s• Abrasive typically quartz• Abrasive size: up to 1 mm• Sample size: 20*15 mm, thickness 5-10 mm• Samples quantity: up to 15 samples

Test Method for Cavitation Erosion Using Vibratory Apparatus• Standard test ASTM G32-10• Vibra-Cell VCX-500 ultrasonic

processor– Allows process control and

monitoring from 1°C to 100°C

Replacable Ti-6Al-4V tip for cavitation testing.

Test parametersFrequency 20 kHz

Amplitude 50 μm

Distance to sample 0.6±0.1 mm

Water temperature 25±1 °C

Tip diameter 13 mm

High Velocity Particle Impactor• Barrel diameter: 9 mm• Shooting distance: 0.5...1.5 m• Pressure system: pressurized air up to

16 bar• Video recording: high speed camera

NAC MEMRECAM up to 80 000 fps• Light system: up to 4 500 W

Trap wallTarget

assemblySpeed

measurementdevice

Smooth bore Pressure control

Pressurizedair tank

Specimen

• Projectiles: e.g. metallic or ceramic ballbearing balls, cylinders, bullets, rocks, …

• Projectile’s speed: 30…200 m/s • Target’s angular position: 0°...90°• Developed for the model verification

Ball-On-Block Impact Wear Testing Device

• Ball-on-block is a high-energy impact wear testing device that produces repeatedly high-energy impacts to the surface of the specimen

• Impacts are created by shooting a ball to the specimen using a pneumatic cylinder

• Simulates wear on a SAG-mill• Ball:

– mass 8 kg and diameter 125 mm– Impact velocity 8-12 m/s (Ek = 256 J – 576 J)– material for example tempering steel

• Specimen:– size 200x200x75 mm or 200x200x50 mm– various materials tested such as steels, rubbers,

metal matrix composites, hard metals

Hammer-mill Type Impact Wear Testing Device

• Two rotating hammers• The abrasive is fed between the hammer and

the specimen from a container through a feeder tube

• Hammers:– Speed: 5,1-9,0 m/s– Impact energy: 21,9-66,9– Typical speed 7 m/s and impact energy 50 J

• Specimen:– 80mm x 80mm – 250mm x 250mm– Thickness 15-45mm

High-speed sliding test rig

• Simulates the high-speed sliding conditions in modern paper-making processes

• Up to four samples can be tested at once

• Slurry composition adjustable• Automated slurry level

adjustment and several self-monitoring features ® test runs can be set up to run for days

• Wear rates are lower than those provided by the ASTM G 65 standard test

Biomaterial crusher • Biomaterial crusher is used to test the wear of cutting blades. The equipment will

be used in field tests.• Biomaterial crusher is fed from the top with belt conveyor • Feeding to cutting blades with hydraulic press • The 14 blades can be changed one by one• Crusher is controlled with programmable logic• The capasity of the crusher is about one cubic meter of biomaterial in one hour

Surface fatigue wear

• Attached to MTS

• Holder moves afterevery step

• Intender ball or spike

Other wear equipment

Dry Sand Rubber Wheel Abrasion Testing Device

Slurry Abrasion Testing Device

Block-on-Ring

Scanning Electron MicroscopeZeiss ULTRAplus

• Ultra high resolution field emission SEM• Detectors: inlens SE, EsB, AsB, Everhart

Thornley SE, and STEM• Resolution 1.0 nm@15 kV and 1.7 nm@1 kV• Accelerating voltage 100 V - 30 kV; beam

current up to 40 nA• Charge compensator for non-conductive

samples• INCAx-act Energy Dispersive X-ray

Spectrometer (EDS)• HKL Premium-F Channel EBSD system with

ultrafast Nordlys F400 detector• SIS Scandium image analysis and processing

software• K1050XT RF Turbo plasma asher

Analytical Transmission Electron Microscope Jeol JEM 2010

Analytical Transmission Electon Microscope (TEM) is equipped with an energy dispersive X-ray spectrometer (EDS) and digital camera system. This microscope is used primarly for studing the structure and chemistry of materials at high spatial resolution.• LaB6 electron source• Point resolution 0.23 nm• ± 30° of eucentric specimen tilt• convergent beam electron diffraction (CBED)

and selected area diffraction (SAED)NORAN VANTAGE Energy Dispersive X-ray spectrometer (EDS) with Si(Li) detectorGATAN ORIUS SC600 digital camera system• 7 megapixel CCD sensor• Peltier cooling

Characterization of wear• Optical and stereo microscopes• Retsch AS 200 analytical sieve shaker• Precica XB4400 ja XT1220 weighers• Veeco WYKO NT1100 optical profilometer

Hopkinson Split Bar, HSB• Based on the propagation of elastic waves in

slender bars• Type of loading: Compression, tension, or

shear.• Duration of the loading pulse [µs]: 50 - 600• Strain rate range [s-1]: 2·102 - 104

• Loading range [kN]: 0 - 250• Temperature range [°C]: -190 - 1000

High rate abrasionwith HSB

High Speed Video Systems

• Cordin 535-16 • High Resolution Rotating Mirror CCD

Framing Camera System. • Number of Frames: 16• Maximum framing Rate: 1 million• Minimum Interframe time: 1.0 us• Minimum Exposure Time: 800 ns• Resolution: 1000 x 1000 pixels• Pixel size: 7.4 x 7.4 mm• Dynamic Range: 10 bit

Memrecam fx K5 • Provides ultra high light sensitivity, ultra

high speed and mega pixel resolution• Megapixel Sensor• Frame rates up to 168,000fps• Ultra-High Light Sensitivity— ISO 5,000

Colour & 32,000 Monochrome• 1280 x 1024 resolution

3D Digital Image Correlation System• LaVision StrainMaster system with

– 2x Photron SA-X2 Cameras– 2x E-Lite low rate high resolution cameras– Zeiss Discovery V.8 Stereomicroscope– Lights and Accessories

Thermal spraying at TUT• Plasma spraying (Plasmatechnic A3000)• Arc spraying (Sulzer Metco 6RC)• Wire flame spraying (Sulzer Metco 12E)• Powder flame spraying (Sulzer Metco 6P-II and

Castolin DS 8000)• Detonation spraying (Perun P D-gun)• High velocity oxygen fuel (HVOF) spraying (Sulzer

Metco DJ Standard and DJ Hybrid)• High velocity air fuel (HVAF) spraying (Uniquecoat

Technologies M3 Supersonic Spray Gun)• Low-pressure cold spraying (Dymet 304K)• High-pressure cold spraying (CGT Kinetiks 3000)

Sprayingmethod

Process temperature

(°C)

Particle velocity

(m/s)

Plasma 12000 200 - 400

Arc 4000 100

Flame 3000 40

Detonation 4000 900

HVOF 3000 800

Cold 25 - 800 550 - 1200FLAME PLASMA

HVOF

ARC

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

www.tut.fi/molwww.tut.fi/twc