International Journal of Mechanical Engineering and Technology (IJMET)

Volume 10, Issue 03, March 2019, pp. 1781–1791, Article ID: IJMET_10_04_180
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

STUDY OF MATERIALS TEST METHODS FOR

WEAR RESISTANCE IN OIL AND MINING
INDUSTRY
Yury Dukhnenko
Department of Lithology
National University of Oil and Gas Gubkin University, Russia

ABSTRACT
The main cause of damage to oil and gas equipment is wear. This paper proves that
the principal wear mechanism is abrasive and shock-abrasive wear; and analyzes
materials test methods and techniques for wear rate identification. The author considers
standardized and non-standardized methods and establishes that despite a large
number of materials test methods, we don’t have a unique one for adequate assessment
of wear resistance in metals. It is concluded that selection of test methods depends on
working conditions of the equipment and use of different types of wear to assess
resistance of metals.
Key words: Wear, wear resistance, metallic materials, rocks, abrasivity, abrasive
wear, shock-abrasive wear
Cite this Article: Yury Dukhnenko, Study of Materials Test Methods for Wear
Resistance in Oil and Mining Industry, International Journal of Mechanical
Engineering and Technology 10(3), 2019, pp. 1781–1791.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=3

1. INTRODUCTION
Modern world development requires a great amount of natural resources. Extraction and
processing of natural resources is impossible without highly efficient equipment with improved
performance [1-5]. The rate of natural resources extraction is limited by a number of factors
associated with mining and geological conditions, environmental safety, equipment
performance, etc. [6-17] High-tech equipment applied in minerals extraction can greatly
influence the mining economy. One of the main factors affecting performance of machines and
equipment is their reliability. Reliability of equipment, to a great extent, depends on durability
of its components. We can improve durability of various components by changing their design,
using new, more durable and wear-resistant materials or finding special technological solutions
to improve these characteristics in the applied materials. A method to increase strength and
durability of materials in machine parts should be selected by taking into account analysis of
operational conditions of equipment. The same material processing technology may have
different effects on wear resistance of a certain material depending on its wear conditions.

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 Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry

Most drilling, oil and gas equipment is subject to significant static and dynamic loads, as
well as intensive wear and corrosion in the course of operation. Apart from that, a large number
of parts operate in abrasive and corrosive environments at high temperatures. In some regions,
temperature can differ from +50 ºC to –50 ºC. Also, as the drilling wells deepen, the bottom-
hole temperature increases, so the main parts of drilling tools operate at the temperature of 200
÷300 ºC.

2. TEST METHODS
2.1. Standardized methods
Operating in highly aggressive environments, parts of mining equipment are subject to
significant wear, which, in turn, leads to their failure [18-27]. The main type of wear in
equipment and machines of the oil and mining industry is wear caused by abrasive particles.
One of the groundbreakers in the study of wear mechanism was Professor
M.M. Khrushchev. It was he or researchers under his supervision who formulated basic
principles of wear process. In particular, a great contribution to the study of abrasive wear
processes in machines of mining and agricultural industries was made by Professor M.M.
Tenenbaum, M.A. Babichev, Dr.-Ing. Karl-Heinz ZumGahr et al. [28, 29].
Wear of metallic materials can follow different pattern and depend on many factors. Quite
often, wear of a drilling tool combines several mechanisms: micro-cutting, peeling, fatigue
failure, chips, etc. [29].
It has been proven [28-31] that destruction of materials in abrasive wear is caused by cutting
or scratching effect of solid particles. Paper [32] summarizes works of various researchers who
studied wear resistance of materials by sclerometric methods, namely, determined scratch
resistance and hardness during indentation. The data obtained for pure metals proved that
hardness and scratch resistance has a straight dependency. However, for steels with different
carbon content or alloyed steels, this dependency is non-linear. Currently, scratching is not
among standard methods for determining wear resistance in materials. However, a foreign
standard ASTM G171 - 03 (2009) e2, which determines the wear resistance of materials and
coatings is a test method for scratch hardness of materials [32]. In Russia we have a similar
national standard GOST 21318-75 "Measurement of micro-hardness by scratch diamond
instruments".

Figure 1. Standard Test Method for materials wear against a loosely fixed abrasive

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 Yury Dukhnenko

In accordance with GOST 30480-97 and GOST 23.208-79, a standardized method of testing
materials for wear resistance is friction against loosely fixed abrasive particles (Figure 1). The
method is based on the Brinell hardness test method, in which specimens of the test and
reference materials are worn with abrasive particles fed into the friction zone and pressed to the
specimen by a rotating rubber roller. In this case assessment of wear is relative in nature [33].
A device with a similar principle is used in the ASTM G65 standard, the only difference is that
the specimen is pressed against the roller in a vertical position.
Test for abrasive wear against rigidly fixed abrasive particles is covered by GOST 17367-
71 “Metals. Method of abrasion test by friction against embedded arrogant grain". The idea
behind this method is that the test and reference specimens are rubbed against the surface with
embedded arrogant grain (abrasive sandpaper) under static load and no heat; then the results
are compared. For reference specimens the method usually uses technically pure annealed
aluminum (a test specimen has hardness less than HV150) or technically pure annealed iron (a
test specimen has hardness less than HV150).
When materials are tested for gas and abrasion wear, another standard is applied - GOST
23.201-78 “Products wear resistance assurance. Gas abrasive wear testing of materials and
coatings with centrifugal accelerator”. The method is based on simultaneous exposure of the
testing and reference specimens to a solid particles flow generated by a centrifugal accelerator
with standard sizes of working elements under fixed test conditions; the wear rate in the test
and reference specimens is measured, then the wear resistance of the material is assessed by
comparing it with the reference specimen wear.
Standard ASTM G76 offers another method. The air flow passes through a mixer, captures
abrasive mixture particles (abrasive) and is fed through a nozzle (nozzle) to the test specimen
(test specimen). Speed of the particles flow depends on the air pressure. Depending on
experimental conditions, the inclination angle of the test specimen may vary (Figure 2).
When testing materials for shock-abrasive wear, researchers usually apply GOST 23.207-
79 “Ensuring of wear resistance of products. Testing of engineering, materials for impact
abrasive wear”. In this method the specimen is repeatedly hammered on a fixed anvil through
a layer of solid abrasive particles, with a given impact energy, speed and frequency of impacts,
then relative wear resistance of the material is assessed by comparing wear of the test and
reference specimens tested in identical conditions (Figure 3).

Figure 2. Standard Test Method for gas abrasive wear under ASTM G76

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 Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry

Figure 3. Standard Test Method for Shock-abrasive wear

One of the standard techniques deliberately developed for the mining industry is ASTM G81.
The principle of this method is based on using of a reduced size jaw-crusher (Figure 4). The
test specimen is a lining plate of the movable crusher jaw (test plates). When crushing the rock,
the movable plate is worn by gouging. This method is comparative, and can be used to compare
different types of lining plates with a reference specimen. It makes sense to use this method in
order to select the most wear-resistant material of the crushers jaws, linings of bodies and ball
mills, teeth of excavator buckets.
In order to test very hard and durable coatings for abrasive resistance, a contour method was
developed and ASTM G174 was created. In this test method a test specimen with the coating is
pressed against an abrasive closed loop. A closed loop is a tape with fixed abrasive particles
with a size of 30 or 3 microns. When the tape is rotated, the coating is rubbed.
Another method ASTM G132 uses a drum with sandpaper attached to it as an abrasive wear
test. Here they use garnet as an abrasive, rather than aluminum oxide or sand. Garnet is more
preferable here because its hardness is comparable with most of mineral inclusions or rocks. In
this experiment the test specimen is pressed and moves along the rotating drum, this ensures
contacts of the specimen with a new abrasive surface at each moment of time. Relative wear
resistance is compared with the reference specimen as an indicator of wear resistance.

Figure 4. Standard Test Method for Gouging Abrasion Test

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 Yury Dukhnenko

ASTM B611 test method has a similar principle to ASTM G65. The only difference of this
method is that the wheel is made of steel and is placed in slurry of water and aluminum oxide
particles together with the test specimen. This method is used in testing cemented carbides for
abrasion resistance [32].
ASTM G105 method is based on testing specimens in a liquid-sand mixture for 1 hour. Test
time may vary depending on the type of material tested. Also, similar to ASTM G65, it uses a
rubber wheel, against which the test specimen is pressed (Figure 5).

Figure 5. Standard Test Method for hydro-abrasive wear of metal specimens under ASTM B105
In addition to standardized methods, there are a large number of other methods aimed at
testing materials for abrasive wear; such methods were developed under the standardized
methods. Most of these techniques are described in [29, 31, 32].
One of the first Russian wear test methods, still widely applied today, is the method
developed by M.M. Khrushchov and M.A. Babichev; it tests wear of the specimens against the
sand paper abrasive surface in the X4-B device [29].
During the test a cylindrical specimen is pressed against the sandpaper abrasive surface.
When the disk rotates and the cylinder simultaneously slides, the specimen moves in a spiral so
that at each moment of time 50% of its working surface rubs against a new abrasive surface,
which ensures homogeneous and uniform abrasive properties of the abrading surface. The
largest radial movement of the specimen is 100 mm. Movement of the specimen is reversible
[34].
The tests are made at relatively low loads (P = 3 N). The results are presented as the ratio
of wear in the reference material to wear in the tested material.
Wear is manifested as a changed linear size of the specimen (in this case, height) during the
test and is determined by measuring height of the specimen before and after the test. Wear can
also be determined by weight reduction - weighing specimens before and after the test on an
analytical balance [34]. A similar method is used in the ASTM G99-05 method.
Another method to study metals wear that occurs due to operating conditions of the ripping
bars in soil-tilling and earthmoving machines is the test method for abrasive compact wear, for
example, using a screw extruder [34].
The abrasive mass is loaded into a hopper, then fed into a cylindrical chamber and,
compacted by the screw, is squeezed out towards the rotating specimen. The test specimen has
a blade shape and is mounted on a faceplate, which rotates at a predetermined number of
revolutions during the test. The shape of the specimen is selected as a blade in order to make
the test conditions as close as possible to real conditions of interaction between the ripping bar
and the abrasive medium. During the test, the abrasive mass extruded by the screw towards the

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 Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry

rotating specimen is cut into a metal box. Wear is determined by measuring linear dimensions
of the specimens before and after the test.

3.2. Non-Standardized Test Methods

Paper [32] gives a summary of standardized methods for testing abrasion resistance (Figure 6).
For instance, the author highlights several basic test methods for wear resistance: when two
disks interact in an abrasive mass (Disk Vs Disk); rubber wheel and dry sand (Dry sand / rubber
wheel); movement of a specimen under stress along a loose abrasive (high stress abrasion);
movement of a specimen under stress along a fixed abrasive (abrasive paper); specimen wear
by milling (wheel with “molded-in” abrasive); abrasion of specimen in the abrasive mass (two
body abrasion tests).

Figure 6. Various abrasive wear test methods

Works [35-40] describe tests of 110G13L and 30HGSA steel for abrasive wear (Figure 7)
using a modified method of L.I. Baron - A.V. Kuznetsova. A steel specimen was pre-weighed
on an analytical balance (weighing accuracy 0.1 mg), secured onto a spindle chuck of the
machine, and pressed with a constant force to the surface of the ore plate. For 60-120 s, the
specimen was worn against the abrasive surface. At the end of the test, the sample was cleaned
from wastes, reweighed, and the weight loss was determined. The same specimen underwent a
series of 5 - 7 tests. Before each test, the ore plate was moved, which ensured contact of the
specimen with the abrasive surface in a new place.

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 Yury Dukhnenko

Figure 7. Schematic diagram for abrasion of metallic materials against rocks

Work [41] describes tests for abrasive wear of agricultural equipment blades in a liquid-
sand mass at a specially designed machine. Specimens of blades are placed in a mixture of
water, sand and pebbles and rotate at a constant speed for 30 minutes. To identify wear
resistance, the authors propose analysis and approximation of the cutting edge shape before and
after the test by using an optical-analytical method.
Work [42] deals with application of a shock-abrasive wear device designed for studying the
effect of shock-abrasive wear on the lining of a ball mill. The device uses wear methods
analyzed in papers [43]. The schematic diagram of the device is shown in Figure 8. Its operation
principle is hammering a fixed specimen against the ore monolith. As a result of shock, the
sample is subject to shock-abrasive wear.

Figure 8. Device (a) to study shock-abrasive wear of materials and its schematic diagram (b)
Similar devices for testing the effect of shock wear in metallic materials were described in
[44-46]. The authors used sand as an abrasive material constantly pouring it onto a roller with
increased hardness; simultaneously the tested material was hammered.

3. CONCLUSIONS
Metallic materials tests for wear require a thorough approach and careful analysis of their
operational conditions. Wear mechanism is determined by characteristics and properties of
materials, which requires a balanced selection of the test method. Quite often, researchers have
to develop a new technique based on typical working conditions of machines and equipment
that makes it possible to adequately assess the wear rate of materials. Selection of only one

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 Study of Materials Test Methods for Wear Resistance in Oil and Mining Industry

method and technique of research cannot show a complete nature of metals destruction. In such
cases, it is advisable to supplement the research with micro-structural analysis, which allows
evaluating the nature of destruction at the level of structural components of materials.

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