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ASTM G40-92 Standard [2] defines corrosive wear as the wear in which chemical or electrochemical
reaction with environment is significant, but it does not consider the synergism between these two
phenomena.
Gunderwar and co-workers [1] verified the synergistic effect between wear and corrosion. They studied
ball wear under three grinding conditions: dry grinding with ore; wet grinding with ore and wet grinding
without ore. The sum of ball wear in dry grinding and wet grinding without ore, was one third of ball
wear in wet grinding with ore. Perez and Moore [3] summarized to three categories of electrochemical
and tribologycal interactions:
a. strain-induced corrosion due to the electrochemical cell development between worn and unworn sites;
b. electrochemical cell development between different phases, for example the metal matrix and the hard
second phase, present in ball material with occurrence of pitting corrosion, and
c. electrochemical cell development between ore and metal.
In this paper, the mass loss results of white cast iron mill balls in dry and wet grinding conditions and the
influence of abrasive particle size distribution on the interaction between corrosion and wear are
presented.
2. MATERIALS AND METHODS
2.1. Balls
50 mm diameter grinding balls were sand-cast and its chemical composition is presented in Table 2.
Table 2 - Chemical composition (mass %) of balls used on grinding tests.
Carbon
Chromium
Silicon
Manganese
Phosphor
Sulfur
2.96
18.00
0.96
1.50
0.04
0.02
The balls were austenitized at 950C for five hours, quenched in forced air stream, and tempered by one
hour at 250C. The final microstructure is a martensitic matrix with 29% volume fraction of M7C3
carbides, less than 5% volume fraction of perlite and 0.4% of retained austenite.
2.2. Abrasive material
The raw abrasive material used for grinding tests was granite with ca. 20% quartz. Its particle size
distribution is presented in Table 3.
The preliminary tests were performed with raw granite and complementary tests were carried out with
coarse particles (greater than 3.36 mm) and fine particles (smaller than 3.36 mm), in order to characterize
particle size influence on corrosion-wear synergism.
% Retained mass
0.00
0.50
4.20
19.6
33.8
15.9
13.7
3.10
1.60
2.80
4.80
3. RESULTS
The accumulated mass losses at the end of each cycle using raw granite, under dry condition and wet
condition, are presented in Figure 1.
Raw Granite
700
600
500
400
300
200
100
0
y = 103.8x - 25.4
y = 51.4x + 1
Wet
Figure 1 Accumulated mass losses with raw granite under dry and wet
conditions.
For each condition, the angular coefficient represents the wear rate. The wear rate under wet condition
were more than twice of those observed under dry condition, showing interaction between corrosion and
wear. Duda [4], in similar experiments using white cast iron balls, in real industrial machine, grinding raw
cement mix slurry (wet) and cement clinker (dry), found two orders magnitude increase in ball wear
under wet conditions. The difference between this authors results and the present paper results can be
attributed to the size of milling machine and to the testing itself: the ball and ground materials.
In order to elucidate the influence of particle sizes on wear and wear corrosion synergism, a new series of
testing using only fine or coarse granites were started. Figure 2 shows the accumulated mass loss in dry
and wet condition with coarse particles only (> 3.36 mm).
Coarse Granite
350
300
250
200
150
100
50
0
y = 57x + 5.8
y = 49.4x + 10
Cycle ( = 6 hours)
Dry
Wet
Figure 2 Accumulated mass losses with coarse granite under dry and wet condition.
In this case, the observed wear rates in two conditions are approximately the same, showing that the
synergistic effect is less pronounced. The difference among material loss rate is about 15%,
demonstrating that particle size presents an important influence on wear and corrosion processes.
Figure 3 shows the mass loss results for fine particles (<3.36 mm) under dry and wet condition.
In Figure 3, the observed behavior is the same for coarse particles, i.e. there is no pronounced interaction
between corrosion and wear, with difference on angular coefficients around 9%.
Fine Granite
700
600
500
400
300
200
100
0
y = 131x - 13.6
y = 120.2x + 3.8
Cycle ( = 6 hours)
Dry
Wet
Figure 3 Accumulated mass losses with fine particles under dry and wet condition.
Figures 4 and 5 show the accumulated mass loss under dry and wet grinding conditions.
Dry Condition
700
600
500
400
300
200
100
0
0
Coarse
Fine
Wet Condition
700
600
500
400
300
200
100
0
0
Cycle (= 6 hours)
Raw
Coarse
Fine
were 2.5 times greater than raw or coarse granite grinding. This relatively high wear rate can be
attributed do the segregation of quartz particles.
2. For wet grinding, the ball material weight loss increased decreasing granite particle size, being
observed 57 mg/cycle for coarse and 131 mg/cycle for fine granite grindings. For raw granite
grinding, the weight loss was 104 mg/cycle, an intermediate value. This can be attributed to the fine
particle agglomeration on coarse particle surface.
3. For wet grinding, synergism or interactions between corrosion and wear was observed. In raw granite
grinding, wear rate under wet condition was two times greater than those observed under dry
condition. For coarse granite grinding, this difference was 15%, for fine granite 9% and for fine
particles the difference war negligible.
REFERENCES
[1] C. S. Gunderwar et al., Int. J. Mineral Processing, 29, 121-139 (1990).
[2] ASTM Standard G40-92, Standard Terminology Relating to Wear and Erosion. Annual Book of
Standards, 03.02, 158-163, ASTM (1992).
[3] R. Perez, J. J. Moore. In: Int. Conf. on Wear of Materials. K. C. Ludema, (Ed.) ASME, 1983.
Proceedings, 67-78.
[4] W. H Duda. Cement Data Book Internationale Verfahrenstechniken der Zementtindustrie.
Wiesbaden, Berlin, Bauverlag (1985).
[5] A. Misra, I. Finnie. Wear, 65, 359-373 (1981).
ACKNOWLEDGMENT
The authors thank to Sao Paulo State Research Support Foundation - FAPESP for the financial support
through Project n. 94/3529-0.