4 th International Conference and Exhibition on Materials Science & Engineering Florida, Orlando, USA, September 14-16, 2015 A. K. Gujba, L. Hackel, D.

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4 th International Conference and Exhibition on Materials Science & Engineering Florida, Orlando, USA, September 14-16, 2015 A. K. Gujba, L. Hackel, D. Kevorkov* and M. Medraj Influence of Impact Speed on Water Droplet Erosion (WDE) Performance of Ti-6Al-4V and Mechanism of Material Removal During the Incubation and Advanced Stages

INTRODUCTION  Gas turbine efficiency in power generation industry is paramount but its adversely affected by ambient temperature.  Fog cooling is employed in order to reduce the temperature by spraying small droplets. 2

INTRODUCTION  Gas turbine efficiency in power generation industry is paramount but its adversely affected by ambient temperature.  Fog cooling is employed in order to reduce the temperature by spraying small droplets. 3 Alstom General Electric

WATER DROPLET EROSION 4 Kong et al Water hammer Shock waves Side jetting Deformation Sub-surface cracks Surface cracks and asperities Main Erosion Mechanisms Hydraulic penetration Deep cracks

WATER DROPLET EROSION 5 Droplet propertiesVelocity, size, flow rate Material properties Hardness, toughness, ultimate resilience Other parameters Kong et al Impact angle, surface roughness… Factors Influencing Water Erosion

WATER DROPLET EROSION TESTING 6 The state of the art rig for liquid impingement erosion testing at Concordia University, Montreal, Canada. Rig parameters Impact speed (m/s) = Droplet size (µm) = Test impact angle ( ⁰ ) = 1-90 Flow rate (liter/min) =

MATERIAL 7  Ti-6Al-4V (ASTM B265, Grade 5) alloy, used for compressor blades in gas turbine, was investigated.  T-shaped coupons, as shown, were machined using a CNC  The microstructure of the Ti-6Al-4V alloy contains α and β phases. Sample geometry β -phase α -phase Top surface Cross section

WATER DROPLET EROSION TESTING 8 The test was done in accordance with ASTM G73 standard for liquid impingement erosion testing. Test parameters Impact speed (m/s) = Av. droplet size (µm) = 460 Test impact angle ( ⁰ ) = 90 Flow rate (liter/min) = 0.05 Nozzle-sample distance (mm) = 5

CHARACTERIZATION OF ERODED COUPONS 9 Only incubation period and maximum erosion rate will be presented in this work

RESULTS – WDE CURVES 10 F. Heymann Incubation period 350m/s 325m/s 300m/s

11 F. Heymann Incubation period Maximum erosion rate ANALYSIS OF WDE CURVES

WDE MECHANISM – INITIATION STAGE 12 A B Incubation stage Advanced stage 0min 6mins 32mins 56mins

WDE MECHANISM – INITIATION STAGE 13 A B Incubation stage Advanced stage

14 WDE MECHANISM – INITIATION STAGE Network of microcracks Potential sites for pit growth and crack propagation Formation of asperities due to impact and side jetting

15 WDE MECHANISM – ADVANCED STAGE Deep tunnel due to hydraulic penetration Material upheaval due to stress wave Stress wave direction Fatigue surface cracks Sub-surface crack from beneath the crater

16 WDE MECHANISM – ADVANCED STAGE Sub-surface cracks Sub-surface cracking Micro jetting effect forming due to hydraulic penetration Material folding (upheaving) Crack propagation due to lateral flow Coupon top surface

Conclusions 17 Higher the impact speed accelerates the erosion initiation and increases erosion rates. Main causes of the erosion damage at early stages are the high impact pressure and the lateral jetting. Formation of microcracks, isolated pits and shallow depressions were typical features associated with the incubation stage. The hydraulic penetration and stress waves are the main causes of erosion in advanced stages. Deep cracks, sub-surface cracks, material folding and upheaving are main features observed at the advanced stage.