Application oriented weartesting equipment

Kati ValtonenTampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

Alihankintamessut 16.9.2015, Tampere

Research Equipment• Wear testing: Crushing pin-on-disk, Uniaxial

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

• Tribology and machine elements test rigs: Test rigsfor journal, thrust, and rolling bearings, FZG, Twin-disc test rig, Fretting wear and fatigue test rigs,Vibration Testing, etc.

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

Crushing pin-on-disc• Crushing pin-on-disc simulates mineral crushing and handling

applications, such as jaw and cone crushers• Contact mode, high loads, large abrasive size, abrasive type, and

the comminution of the abrasive form the basis for the tests• Variables: abrasive, disc (indirect counterpart), load (200-500N)• Typical test parameters: 2-10 mm rock, structural steel disc, 240

N, 90 min test time ® 60 min contact time

Uniaxial Crusher• The equipment crushes the abrasive uniaxially

between two specimens with a high pressure• Controlled amount of the abrasive• Simulates mineral crushing, like in the high pressure

grinding rolls or cone crusher• 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

• Typical test parameters:• 4-6.3 mm granite• Tool steel counterpart• 53 kN• 1000 cycles

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

jaw crusher for studying themechanisms of abrasive wear duringmineral 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 atany combination of compressive and slidingabrasion

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

the test geometry, enabling accurate controlof the compression-sliding ratio.

– versatile instrumentation for monitoring thewear processes, including piezoelectricforce sensors, high speed video systems,etc.

Dual pivoted jaw crusher

Compressioncompression/sliding ratio 10:1

Slidingcompression/sliding ratio 1:8

Impeller-Tumbler Impact-Abrasive Wear Tester• Simulates wear in mineral handling applications, such as earth moving

machinery and impactor plants.• During the test, an impeller with three samples rotates (700 rpm) inside a

rotating tumbler (30 rpm) filled with gravel.– Variables: sample angle, gravel size distribution, type, and amount– One sample is the reference ® changes in mineral composition controllable

• Typical test parameters: 900 g 8-10 mm rock, 15 min cycle (4...24x)

High-speed slurry-pot• Testing of wear resistant materials

and mineral abrasiveness in highstress erosive or abrasive wearconditions (slurry or dry)

– mining and mineral processingapplications, dredging, pumps, ...

• Key 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

– edge protection possibility– flow conditions vary in 4 sample

levels ® requires sample rotation

High Velocity Particle Impactor• Developed for the model verification and to identify the basic

mechanisms influencing the impact wear and failure behavior of materials• Key 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

Conclusions• The scientific understanding of the wear phenomena and

wear mechanisms is the basis for sustainable materialsolutions.

• In challenging conditions, like in mining and mineralprocessing, material selection for wear parts has amarked impact on energy and cost efficiency.

• Selecting of the best possible testing approach for eachcase, it is important to have a good understanding of therelevance of the laboratory wear tests in predicting the in-service performance of materials in high stress wearconditions ® utilization of the laboratory test results morestraightforward for the industry.– Several different laboratory test methods are needed to

properly cover this kind of severe in-service conditions

TWC International Wear SeminarTribological challenges in industrial applications

28.10.2015

Contact

Kati ValtonenTampere University of TechnologyDepartment of Materials ScienceTampere Wear Center

http://www.tut.fi/twc/® Alihankintamessujen seminaari