Investigation of Slurry Erosion Wear Behavior of Ti-6Al-4V Alloy Using Response Surface Methodology

Slurry erosion wear poses a significant challenge, impacting the efficiency and lifespan of components handling particle-entrained slurries. The Ti-6Al-4V (grade 5) alloy, renowned for its lightweight nature, corrosion resistance, and strength, finds widespread application across various industries. In this research work, the slurry erosion wear response of Ti-6Al-4V (grade 5) alloy was studied. The study employs response surface methodology to model and optimize key input parameters, including impact angle (30°, 60°, & 90°), impact velocity (15, 20, & 25 m/s), and slurry concentration (2, 6, & 10 wt.%). Erosion tests were conducted using a slurry jet erosion tester, with aluminum oxide serving as the erodent material. The experimental results revealed that the mass loss increased by increasing the impact velocity and slurry concentration. The mass loss was observed to be maximum at a low impingement angle. The analysis of variance (ANOVA) results show that the slurry concentration was the most significant factor influencing mass loss, and surface roughness was influenced by impact velocity. The XRD and microhardness study of the eroded samples revealed phase transformation and increased hardness due to the work hardening at high-angle impact. The crater topography and depth were assessed using the 3D profilometer. The SEM analysis reveals the ductile erosion behavior of Ti-6Al-4V alloy.