Full definition
Abrasive wear refers to the gradual degradation of material from a surface due to the mechanical action of hard particles, which can be mineral, ceramic, or metalite. This wear mechanism is particularly prevalent in industries such as mining, quarrying, cement production, agriculture, and earth-moving, where the harsh operating conditions expose equipment to constant abrasive forces. Globally, the costs associated with abrasive wear are staggering, estimated to exceed $100 billion annually. Understanding the different types of abrasive wear is crucial for material selection and equipment longevity.
Abrasive wear can be classified into three main categories based on the angle of particle impact. Low-angle erosion occurs when particles slide along the surface at angles less than 30°, where the hardness of the material significantly influences its wear resistance. Materials such as steel, ceramic, and chrome are typically favored in these scenarios due to their high hardness. Conversely, high-angle impact, characterized by an angle greater than 45°, sees particles striking the surface nearly perpendicularly. In this case, the resilience of the material becomes critical, with rubber, particularly natural rubber (NR), outperforming steel by a factor of 5 to 10 due to its ability to absorb impact energy elastically.
The third category, gouging, occurs when large particles exert high stress on the surface. In this scenario, toughness is the key property that governs resistance, with austenitic manganese steel, commonly referred to as Hadfield steel, demonstrating excellent work-hardening properties under impact. Measurement of abrasive wear can be quantified in terms of volume loss (in mm³), typically determined through laboratory tests such as ASTM G65 for dry sand or DIN 53516 for rubber abrasion. Alternatively, thickness loss can be assessed in the field in mm/year. Material selection for applications involving abrasive wear must take into account the specific wear mechanism, the characteristics of the abrasive particles, and the prevailing operating conditions, as no single material excels in all types of abrasive environments.