Wear and corrosion of mechanical seals

Mechanical seals are used extensively to seal machinery such as pumps, mixers and agitators in the oil, petrochemical and chemical industries. The performance of such machinery is critically dependent on these devices. Seal failures may result in the escape of dangerous chemicals, possibly causing injury or loss of life. Seal performance is limited by the choice of face materials available. These range from cast iron and stellited stainless steel to cemented and silicon carbides. The main factors that affect seal performance are the wear and corrosion of seal faces. This research investigated the feasibility of applying surface coating/treatments to seal materials, in order to provide improved seal performance. Various surface coating/treatment methods were considered; these included electroless nickel plating, ion plating, plasma nitriding, thermal spraying and high temperature diffusion processes. The best wear resistance, as evaluated by the Pin-on-Disc wear test method, was conferred by the sprayed tungsten carbide/nickel/tungsten-chromium carbide deposit, produced by the high energy plasma spraying (Jet-Kote) process. In general, no correlation was found between hardness and wear resistance or surface finish and friction. This is due primarily to the complexity of the wear and frictional oxidation, plastic deformation, ploughing, fracture and delamination. Corrosion resistance was evaluated by Tafel extrapolation, linear polarisation and anodic potentiodynamic polarisation techniques. The best corrosion performance was exhibited by an electroless nickel/titanium nitride duplex coating due to the passivity of the titanium nitride layer in the acidified salt solution. The surface coating/treatments were ranked using a systematic method, which also considered other properties such as adhesion, internal stress and resistance to thermal cracking. The sealing behaviour of surface coated/treated seals was investigated on an industrial seal testing rig. The best sealing performances were exhibited by the Jet-Kote and electroless nickel silicon carbide composite coated seals. The failure of the electroless nickel and electroless nickel/titanium nitride duplex coated seals was due to inadequate adhesion of the deposits to the substrate. Abrasion of the seal faces was the principal wear mechanism. For operation in an environment similar to the experimental system employed (acidified salt solution) the Jet-Kote deposit appears to be the best compromise.

Abrasion resistance of fibre reinforced concrete floors

This thesis focuses on the investigation of the abrasion resistance of fibre reinforced concrete floors at both the macro and micro levels. A literature review of the available literature concerning subjects allied to the current project is included. This highlights themes relevant to wear mechanisms and the factors influencing it: factors that affect the abrasion resistance of concrete and several test methods for assessing it; and the historical development of fibres and the properties of different fibre types and their influence on concrete. Three accelerated abrasion testers were compared and critically discussed for their suitability for assessing the abrasion resistance of concrete floors. Based on the experimental findings one accelerated abrasion apparatus was selected as more appropriate to be used for carrying out the main investigations. The laboratory programme that followed was undertaken to investigate the influence of various material and construction factors on abrasion resistance. These included mix variations (w/c ratio), fibre reinforcement, geometry, type and volume, curing method and superplasticizing agents. The results clearly show that these factors significantly affected abrasion resistance and several mechanisms were presumed to explain and better understand these observations. To verify and understand these mechanisms that are accountable for the breakdown of concrete slabs, the same concrete specimens that were used for the macro-study, were also subjected to microstructutural investigations using techniques such as Microhardness examination, Mercury intrusion porosimetry and Petrographic examination. It has been found that the abrasion resistance of concrete is primarily dependent on the microstructure and porosity of the concrete nearest to the surface. The feasibility of predicting the abrasion resistance of fibre reinforced concrete floors by indirect and non-destructive methods was investigated using five methods that have frequently been used for assessing the quality of concrete. They included the initial surface absorption test, the impact test, ball cratering, the scratch test and the base hardness test. The impact resistance (BRE screed tester) and scratch resistance (Base hardness tester) were found to be the most sensitive to factors affecting abrasion resistance and hence are considered to be the most appropriate testing techniques. In an attempt to develop an appropriate method for assessing the abrasion resistance of heavy-duty industrial concrete floors, it was found that the presence of curing/sealing compound on the concrete surface at the time of accelerated abrasion testing produces inappropriate results. A preliminary investigation in the direction of modifying the Aston accelerated abrasion tester has been carried out and a more aggressive head has been developed and is pending future research towards standardisation.

Hydrostatic pressure sensing using a polymer optical fibre Bragg gratings

The sensitivity of a fibre Bragg grating (FBG) sensor fabricated in polymer optical fibre (POF) to hydrostatic pressure was investigated for the first time. In this initial investigative work a reflected Bragg response of a FBG fabricated in multimode microstructured POF (MMmPOF) was monitored, whilst the hydrostatic pressure was increased up to 10MPa. Positive sensitivities were observed, meaning a positive wavelength shift to increasing pressure, as opposed to negative sensitivities monitored when using a FBG sensor fabricated in silica optical fibre. The FBG sensors fabricated in the MMmPOF gave fractional changes in wavelength and hence sensitivities of at least 64.05×10-6/MPa, which is some 25 times larger than the -2.50×10-6/MPa sensitivity of a FBG sensor fabricated in silica optical fibre that was measured in this work. Furthermore this work highlighted a decrease in sensitivity of the FBG sensor fabricated in the MMmPOF by some 50% by sealing the holes of the mPOF at the tip of the fibre with an adhesive. This offers the potential to tailor the response of the sensor to hydrostatic pressure.

Hydrostatic pressure sensing using a polymer optical fibre Bragg gratings

The sensitivity of a fibre Bragg grating (FBG) sensor fabricated in polymer optical fibre (POF) to hydrostatic pressure was investigated for the first time. In this initial investigative work a reflected Bragg response of a FBG fabricated in multimode microstructured POF (MMmPOF) was monitored, whilst the hydrostatic pressure was increased up to 10MPa. Positive sensitivities were observed, meaning a positive wavelength shift to increasing pressure, as opposed to negative sensitivities monitored when using a FBG sensor fabricated in silica optical fibre. The FBG sensors fabricated in the MMmPOF gave fractional changes in wavelength and hence sensitivities of at least 64.05×10-6/MPa, which is some 25 times larger than the -2.50×10-6/MPa sensitivity of a FBG sensor fabricated in silica optical fibre that was measured in this work. Furthermore this work highlighted a decrease in sensitivity of the FBG sensor fabricated in the MMmPOF by some 50% by sealing the holes of the mPOF at the tip of the fibre with an adhesive. This offers the potential to tailor the response of the sensor to hydrostatic pressure.

The application of laser welding on Left Ventricular Assist Device (LVAD)

A successful and useful treatment for end-stage heart failure is Left ventricular assist device (LVAD). An important part - a hydrodynamically suspended impeller exposed to corrosive conditions, required to sealed hermetically into micro packages. Laser beam welded (LBW) Ti6Al4V alloy has been adopted in anti-corrosion micro packages for the impeller of a (LVAD). Thin and narrow welds were required for such medical equipment. Pulsed Nd:YAG welding was successfully adopted as sealing method for the impeller. ©2011 IEEE.