UDK 669.715:621.78 Professional article/Strokovni članek ISSN 1580-2949 MTAEC9, 48(1)141(2014) THE EFFECT OF HEAT TREATMENTS ON THE SOLID-PARTICLE EROSION BEHAVIOR OF THE ALUMINUM ALLOY AA2014 VPLIV TOPLOTNE OBDELAVE ZLITINE AA2014 NA VEDENJE PRI EROZIJI S TRDNIMI DELCI Sedat Karabay Mechanical Engineering Department of Engineering Faculty of Kocaeli University, Kocaeli, Turkey sedatkarabay58@gmail.com Prejem rokopisa — received: 2013-03-18; sprejem za objavo - accepted for publication: 2013-05-20 In this study the solid-particle erosion behaviour of solutionised, artificially aged (T6) and annealed specimens prepared from an extruded aluminium alloy AA2014 was investigated and an intercomparison was made. The samples were eroded in specially designed, solid-particle erosion test equipment at a 45° impingement angle and 75 m/s impingement velocity by using 180-mesh garnet erodent particles. Microstructures of the solutionised, artificially aged and annealed samples from the AA2014 were obtained using a light microscope. Moreover, the Vickers hardness of the samples exposed to different heat treatments was measured in order to evaluate the erosion rates with respect to the ductility changes in the material. Additionally, the surface morphology images of the samples were taken before and after the erosion test using a scanning electron microscope (SEM). The results showed that the heat treatments dramatically affected the erosion rates of the samples. However, artificially aged samples caused decrease reduction of the erosion resistance of the AA2014 aluminium alloy. The solutionised alloy showed the best erosion resistance compared to the precipitation hardening (T6) and annealed samples. The effects of the microstructures and the hardness on the erosion behaviour of the different heat-treated specimens were discussed. Finally, SEM images of the samples were analyzed in detailed and the erosion mechanism occurring on the surfaces of the samples was discussed. Keywords: AA2014, impingement angle, erosive loss, erodent particle, flake, craters V tej študiji je bila izvršena preiskava in primerjava vzorcev, izdelanih iz ekstrudirane aluminijeve zlitine AA2014, raztopno žarjenih, umetno staranih (T6) in mehko žarjenih, na vedenje pri eroziji s trdnimi delci. Vzorci so bili erodirani v posebno konstruirani napravi za preizkušanje erozije s trdnimi delci pri naklonu udarca 45° in hitrosti udarca 75 m/s, pri uporabi delcev granulacije 180. S svetlobno mikroskopijo je bila pregledana mikrostruktura raztopno žarjenih, umetno staranih in popuščanih vzorcev iz AA2014. Izmerjena je bila tudi trdota po Vickersu vzorcev, izpostavljenih različnim toplotnim obdelavam, da bi opredelili hitrost erozije glede na spremembe plastičnosti materiala. Z vrstičnim elektronskim mikroskopom (SEM) smo dodatno napravili tudi posnetke morfologije površine vzorcev pred preizkusom erozije in po njem. Rezultati so pokazali, da toplotna obdelava vzorcev močno vpliva na hitrost erozije. Vendar pa je umetno staranje vzorcev povzročilo zmanjšanje odpornosti proti eroziji zlitine AA2014. Raztopno žarjena zlitina je pokazala najboljšo odpornost proti eroziji v primerjavi z izločevalno utrjenimi (T6) in mehko žarjenimi vzorci. Komentiran je tudi vpliv mikrostrukture in trdote različno toplotno obdelanih vzorcev na vedenje pri eroziji. SEM-posnetki vzorcev so detajlno analizirani in opisani so mehanizmi erozije, ki so se pojavili na površini. Ključne besede: AA2014, naklon udarca, izgube pri eroziji, erozijski delec, luske, kraterji 1 INTRODUCTION Applications for the 2xxx series alloys include the internal and external structures of aircraft, the structural beams of heavy dump and tank trucks and trailer trucks, the fuel tanks and booster rockets of the space shuttle and internal railroad car structural members. AA2014 is the most popular type of 2xxx series group for producing mechanical constructions. It is obvious that all of these parts are exposed to various types of particle erosion following the completion of the construction.1 Erosion is described as the progressive loss of original material from a solid surface due to a mechanical interaction between the surface and a fluid, which may be a multi-component fluid or impinging solid or liquid particles. It is common that the materials used in pipes, bends and tanks, etc., in industries like chemical, cement, mining and mineral processing and thermal power plants encounter erosion-related problems. Pulveriser mill components, multiple port outlet, orifice, PF (packet filter) bends, elbow, burner assembly, pressure parts, ID (induced draft) fan blade and coal ash slurry pipes are the main components affected by erosion in thermal power stations. There has always been an attempt to reduce the material loss due to erosion as it incurs a huge loss of the material. In the past few decades, researchers have focused on the study of material loss in order to conserve both material and energy.2 A wide variety of methods were adopted to protect materials from the problems of wear, including the use of efficient materials,3 processing techniques,4 surface treatments5,6 of the exposed components and the use of engineering skills leading to a reduced impact of wear on the material, such as an appropriate impingement angle of the erodent and the velocity of the slurry. The methodology to be followed for the protection of the material is adopted from the conclusions drawn from the simulated test carried out for the purpose. Investigations and studies provide an insight into the mechanisms of material removal during the wear process of the material.7,8 There are a number of methods to evaluate the erosion wear of materials using equipment, such as small feed rate erosion test equipment,9 particle jet erosion test equipment,10 coriolis erosion tester11 and slinger erosion test equipment.12 In this study, the solid-particle erosion behaviour of solutionised, artificially aged and annealed condition of AA2014 aluminium alloy has been investigated and compared to each other. The samples were eroded in specially designed solid-particle erosion test equipment. The equipment was designed using ideas presented for different test conditions and materials in the literature.912 In performing the experiments, the particle-impingement angle, the velocity and the pressure were kept constant and different heat-treated samples were eroded in same test conditions for the test equipment. Furthermore, aluminium alloys exhibit ductile erosion behaviour by showing maximum erosion rates at acute angles (15°-45°). Hence, a 45° impingement angle was used in order to erode the samples effectively. The 75 m/s impingement velocity with 3 bar gas pressure was selected for the optimum erosion of ductile materials by using 180-mesh garnet erodent particles.5-7,9-12 Increasing the velocity may cause the breaking of the garnet erodent particles owing to impacting on the metal surfaces. The test set up has versatile properties and all the parameters are also changeable with the special mechanisms to perform different test conditions. The microstructures of the solutionised, artificially aged and annealed AA2014 specimens were obtained using a light microscope and an SEM. Moreover, the erosion rates of the samples versus the thermal treatment grades of the AA2014 were calculated and the surface morphologies of the samples were presented by interpreting before and after the erosion tests. 2 EXPERIMENTAL 2.1 Material and Applied Heat Treatments Initially, the diameter 152 mm (6 inch) AA2014 extrusion billet, with the chemical composition presented in Table 1, was produced by an industrial vertical air slip DC casting unit and homogenised at 480 °C for 12 h. The billet was subsequently heated to 430 °C and extruded into a diameter bar 100 mm. Table 1: The chemical composition of the alloy AA2014 for particle erosion tests in mass fractions, w/% Tabela 1: Kemijska sestava zlitine AA2014 za preizkus erozije z delci v masnih deležih, w/% Al Si Fe Cu Mn Mg Zn Cr Ti Pb 92.92 0.35 0.56 4.56 1.06 0.28 >0.15 0.01 0.02 0.01 Samples from a square cross-section of AA2014 alloy from the extruded bar were cut out (transverse section of extruded bar) with a size of 40 mm x 40 mm x Figure 1: Solid particle erosion test equipment Slika 1: Naprava za preizkusanje erozije s trdnimi delci 3 mm. The samples were divided into three separate groups. The first group was soaked at 570 °C for 2 h to achieve the solution heat-treated state and water quenched. The second group was additionally soaked at 160 °C for 12 h to achieve T6 precipitation. Finally, the last group, after T6, was soaked at 410 °C for 3 h to achieve annealing. All the heat treatments were carried on in an electronically operated Severn heat-treating furnace. 2.2 Erosion test The erosion tests were performed in a horizontal sand-blast type erosion test equipment. Figure 1 shows a schematic illustration of the erosion test equipment. Garnet particles with a size of 180-mesh driven by a static air pressure of 3 bar were accelerated along a nozzle 50 mm of diameter 5 mm. The velocity of the particles under 3 bar pressure was 75 m/s measured using the double-disc method. All the erosion experiments were run at a 75 m/s particle-impingement velocity and a 45° angle of impingement (angle of highest wear rates achieved) by using 180-mesh garnet particles. The samples were cleaned with air blasting before and after the erosion tests in order to remove the sand and dust particles, and then the samples were weighed in an electronic balance with an accuracy of ± 0.1 mg. 2.3 Hardness The hardness of heat-treated samples was measured with a Shimazdu HMV Vickers hardness setup. The test load 300 g and the dwell time 20 s were applied and reported as the average of a minimum 5 readings (HV 0.3). The hardness results were evaluated by generating the hardness graph versus the mass loss. 2.4 Scanning electron microscope To characterize the morphology of the eroded surfaces and in order to understand the material-removal mechanism, the eroded surfaces of the samples were Figure 2: SEM image of longitudinal section of hot-extruded AA2014 Slika 2: SEM-posnetek vzdolžnega prereza vroče ekstrudiranega AA2014 examined using a scanning electron microscope Tescan Vega Sbu-II (Bruker EDS). 3 RESULTS AND DISCUSSION 3.1 Microstructure Elongated a-Al grains and intermetallic precipitates were settled in the hot-extruded AA2014 bar (Figure 2). In the analysis of the structure by SEM, two different types of intermetallic particles with different contrasts were observed at the a-Al grain borders. These are the light- and dark-gray intermetallic particles. The EDS analysis of the light-gray particles reveals a reflection of the Al and Cu signals. However, dark-grey particles additionally reflected the Si, Mn and Fe signals. According to the XRD spectrum, the light- and dark-grey particles are the soluble Al2Cu and the insoluble cubic ac-Ali2(Fe, Mn, Cu)sSi, respectively, as seen in Figure 3. The lack of evidence for recrystallisation across the section of the hot-extruded bar implies that the deformation introduced during the extrusion process is restricted by the pinning effect of the Al2Cu. According to the EDS analysis (Figures 4b to 6b) of the grain boundaries of the solutionised sample, it was clearly detected that there was no response of the Al2Cu signals. Heating the samples at 570 °C for 2 h resulted in a fully solutionised structure and the dissolution of the soluble eutectic Al2Cu into the matrix. Also, the remaining of intermetallics verify the insolubility of ac-Al12(Fe, • : A!,j » 2 Vr.-v - H 'i-' -V^v X \\ n - >- ■■ w . v 1V . . SEM MAC 625 * Det 6SÈ 100 Mm Dsto