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Comprehensive study of the abrasive wear and slurry erosion behavior of an expanded system of high chromium cast iron and microstructural modification for enhanced wear resistance Open Access


Other title
Wear resistance
Slurry erosion
Microstructural refinement
White iron
High chromium cast iron
Type of item
Degree grantor
University of Alberta
Author or creator
Chung, Reinaldo J
Supervisor and department
Li, Dongyang (Chemical and Materials Engineering)
Examining committee member and department
Eadie, Reginald (Chemical and Materials Engineering)
Chen, Weixing (Chemical and Materials Engineering)
Papini, Marcello (Mechanical and Industrial Engineering, Ryerson University)
Ru, Chong-Qing (Mechanical Engineering)
Li, Leijun (Chemical and Materials Engineering)
Department of Chemical and Materials Engineering
Materials Engineering
Date accepted
Graduation date
Doctor of Philosophy
Degree level
High chromium cast irons (HCCIs) have been demonstrated to be an effective material for a wide range of applications in aggressive environments, where resistances to abrasion, erosion and erosion-corrosion are required. For instance, machinery and facilities used in mining and extraction in Alberta’s oil sands suffer from erosion and erosion-corrosion caused by silica-containing slurries, which create challenges for the reliability and maintenance of slurry pumping systems as well as other processing and handling equipment. Considerable efforts have been made to determine and understand the relationship between microstructural features of the HCCIs and their wear performance, in order to guide the material selection and development for specific service conditions with optimal performance. The focus was previously put on a narrow group of compositions dictated by ASTM A532. However, with recent advances in casting technology, the HCCI compositional range can be significantly expanded, which potentially brings new alloys that can be superior to those which are currently employed. This work consists of three main aspects of study. The first one is the investigation of an expanded system of white irons with their composition ranging from 1 to 6 wt.% C and 5 to 45 wt.% Cr, covering 53 alloys. This work has generated wear and corrosion maps and established correlation between the performance and microstructural features for the alloys. The work was conducted in collaboration with the Materials Development Center of Weir Minerals in Australia, and the results have been collected in a database that is used by the company to guide materials selection for slurry pump components in Alberta oil sands and in other mining operations throughout the world. The second part consists of three case studies on effects of high chromium and high carbon, respectively, on the performance of the HCCIs. The third aspect is the development of an approach to enhance the wear resistance of HCCIs by microstructural modification through addition of strong carbide-forming elements to produce eutectic microstructures reinforced with in-situ formed foreign carbides. Very promising results have been obtained in lab, which demonstrates that the approach is feasible and effective in tailoring HCCIs for improved performance.
Permission is hereby granted to the University of Alberta Libraries to reproduce single copies of this thesis and to lend or sell such copies for private, scholarly or scientific research purposes only. Where the thesis is converted to, or otherwise made available in digital form, the University of Alberta will advise potential users of the thesis of these terms. The author reserves all other publication and other rights in association with the copyright in the thesis and, except as herein before provided, neither the thesis nor any substantial portion thereof may be printed or otherwise reproduced in any material form whatsoever without the author's prior written permission.
Citation for previous publication
Chung, R.J., et al., Microstructure refinement of hypereutectic high Cr cast irons using hard carbide-forming elements for improved wear resistance. Wear, 2013. 301(1-2): p. 695-706.Chung, R.J., et al., Effects of titanium addition on microstructure and wear resistance of hypereutectic high chromium cast iron Fe-25wt.%Cr-4wt.%C. Wear, 2009. 267(1-4): p. 356-361.Chung, R.J., et al., Abnormal erosion-slurry velocity relationship of high chromium cast iron with high carbon concentrations. Wear, 2011. 271(9-10): p. 1454-1461.Tang, X.H., et al., Microstructure of high (45 wt.%) chromium cast irons and their resistances to wear and corrosion. Wear, 2011. 271(9-10): p. 1426-1431.Tang, X.H., et al., Variations in microstructure of high chromium cast irons and resultant changes in resistance to wear, corrosion and corrosive wear. Wear, 2009. 267(1-4): p. 116-121.

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