Microstructural Design for Enhanced Erosion Resistance in High Chromium Cast Irons

Abstract Solid particle erosion remains a critical issue in many engineering applications. High chromium cast irons (HCCIs) are favored for their superior erosion resistance and cost-effectiveness. This work quantifies how carbide spacing and erodent size affect the erosion resistance of an HCCI, tested using Arizona test dust (ATD) as the erodent powder per the ASTM G76 standard. Metallography established mean free paths between carbides, guiding particle selection, while a combined experimental/numerical approach assessed velocity- and energy-dependent wear. Weight loss data and scanning electron microscope (SEM) of worn surfaces show material loss rises with impact velocity, while both matrix and carbides contribute. Erosion resistance improves when carbide blocks are closely spaced and coarser, underscoring the need for tailored HCCI compositions for erosion-prone services.