Processing, characterization, and parametric analysis of erosion behavior of epoxy‐LD sludge composites using Taguchi technique and response surface method

Abstract

Linz‐Donawitz sludge (LDS) are the microsized solid particles that are recovered after wet cleaning of the gas emerging from basic oxygen furnace during steel making. This article reports on the development of a new class of thermoset polymer composites filled with this industrial waste called LDS. It includes processing, characterization and solid particle erosion wear of epoxy composites filled with different proportions (0, 5, 10, 15, and 20 wt%) of LDS by solution casting technique. The solid particle erosion wear tests are performed on the prepared epoxy‐LDS composite specimens as per ASTM G76 using Taguchi's Orthogonal Arrays followed by the parametric appraisal of the wear process by Response Surface Methodology (RSM). A theoretical model is developed to estimate the erosion rate of these composites under different test conditions. The results obtained from the proposed theoretical model are found to be in good agreement with the experimental values under similar test conditions. Both Taguchi's analysis and RSM suggest that the filler content and the impact velocity are the most significant factors affecting the erosion rate of the composite specimens. POLYM. COMPOS., 39:E2283–E2297, 2018. © 2017 Society of Plastics Engineers

Fabrication of waste bagasse fiber‐reinforced epoxy composites: Study of physical, mechanical, and erosion properties

“…This trend in erosive wear rate for all the composites can be explained according to the area of erodent impact on the target surface. Many studies demonstrated striking area generated by erodent particles impacting a target surface remain maximum at 60° . Any deviation in impingement angle will results in lowering the striking area of erodent.…”

“…Lower striking area means reduced surface deformation and hence reduced erosive wear rate. Similar results were reported by Prakash et al and A. Purohit and A. Satapathy where maximum erosive wear rate was observed at 60° of impingement angle indicating semi‐brittle erosion behavior.…”

“…Figure c shows the formation of deep crater due to penetration of erodent striking the composite surface at an impingement of 90°. It is well reported in literature that impingement angle is one of the most important control factors in erosion performance . When the erodent's hit the composite surface at low angles, the force of impact can be divided into two, that is, horizontal and vertical force components .…”

Tribological Performance of Composites Reinforced with the Agricultural, Industrial and Post-Consumer Wastes: A Review

“…The authors observed that LD slag content is a significant control factor for minimizing the erosion rate of the produced composites. Numerous publications of Purohit and Satapathy studied the influence of LD slag, LD sludge and BF slag on the sliding wear and erosion wear of the composites based on epoxy resin matrix [ 72 , 73 , 74 , 75 ]. The obtained results indicated that with increasing content of filler, both erosion wear- and sliding wear resistance of the composites increases.…”

Effect of crump rubber on the solid particle erosion response of epoxy composites

“…Property map to compare the erosion rate of E0, EC‐10, EC‐20 and EC‐30 samples at various angles of impingement (30, 45, 60 and 90°) with the existing studies is presented in Figure 13 11,17,45,47,53,56–61 . Results obtained from present study and data extracted from existing literature are mapped with respect to density of the samples.…”