THE UNIVERS I T Y O F I C H I GAN College of Engineering Department of Nuclear Engineering Laboratory for Fluid Flow and Heat Transport Phenomena Report No. AMPP-344-1 -T 01357-3-T PRELIMINARY RESULTS: ASTM ROUND-ROBIN TEST WITH VIBRATORY CAVITATION AND LIQUID IMPACT FACILITIES (6061-T 6511 ALUMINUM ALLOY, 316 STAINLESS STEEL, COMMERCIALLY PURE NICKEL) C.. hb ao F. C., *Hammnitt C. L. Kfrng Financial Support Provided by: Michigan Memorial Phoenix Project Grant No. 344 and National Science Foundation Grant No. GK-1889 April 1968

Abstract A "round robin" test program using three materials of widely varying mechanical properties is being conducted under the auspices of the ASTM Committee G-2 on Erosion by Cavitation or Impingement. The purpose of this test program is to study the variation in results produced by several laboratories ostensibly operating under the same conditions. Of the twelve laboratories taking part in this program, eight have reported results using vibratory cavitation damage facilities; and one has reported results using an impingement damage facility. The data from these labs are represented on various damage or damage rate vs. time curves. These results show that all labs rank the materials in the same order; however, when data on one material from different laboratories are plotted on the same graph, a very substantial spread is found. ii

Acknow edgments The authors would like to acknowledge especially the assistance of Dr. Robert Cheesewright of the 1;echanical Engineering Department, (ueen Mary College, University of London, London, England (formerly visiting Assistant Professor, Nuclear Engineering Department, University of Michigan) in the planning of this report and in helpful criticisms during its preparation. We would also like to acknowledge the assistance and helpful criticisms of Prof. C. A. Siebert of the Chemical and Metallurgical Engineering Department of this University. In addition Messrs. D. J. Kemppainen and E. E. Timm, research assistants of this laboratory are largely responsible for the planning and conducting of our portion of the test work. iii

TABLE OF CO'NTENTS Page Abstract....................... ii Acknowledgements ****..******** i i Table of Contents................ iv List of Tables.............*. v I. Introduction...........I... 1 II. Material Properties........ 3 III. Testing Conditions of Individual Labs..... 4 IV. Erosion Damage Data Comparison........... 9 V. Discussion of Results............. 12 References............. 15 Appendix............*..... 16 iv

LIST OF TABLES Table Page 1 Material Properties............. 6 2-A Testing Conditions for Vibratory Facilities. 7 2-B Testing Conditions for Impingement Facilities 8 3 Material constants for IDP Conversion... 10 v

I. INTRODUCTION One objective of ASTM Committee G-2 on Erosion by CaviLation or Impingement has been to establish a standard vibratory test for cavitation damage. In order to investigate more realistically than has hitherto been possible the effect on the results from such a test of the different parameters which characterize the various test facilities a "round robin" test program has been initiated with three standard materials covering a wide range of mechanical properties. The materials used by each laboratory are identical, coming from the same heat and in many cases the same piece of bar stock. As far as seemed reasonably practicable the test conditions to be used in the various laboratories have been specified (see Appendix); however, a complete identity of test conditions is not possible because of the inherent differences in the various laboratory Facilities. It is thus part of the objective of the "round robin" test to determine the importance of these various parameters, as well as the effect of the minor variations between facilities ostensibly operating at the same conditions. To investigate the general applicability of the results to other cavitation and/or impingement erosion processes, it is desirable that the same three standard materials be evaluated in other forms of test apparata. For this reason tests in liquid-impact facilities have been projected in addition to the vibratory cavitation tests. The laboratories which have agreed to participate in the "round robin" project are: 1. National Engineering Laboratory (NEL), East Kilbride, Glasgow, Scot land 1

2. NASA Lewis Center, Cleveland, Ohio 3. University of Mininesota,'ialapolis, Ninnesota 4. Monsanto Chemical Company, St. Louis, Missouri 5. California Institute of Technology (CIT), Pasadena, California 6. Naval Applied Science Laboratory (NASL), Brooklyn, New York 7. Hydronautics Inc., Laurel, Maryland 8. Westinghouse Electric Corp., Lester, Pennsylvania 9. General Motors Corp. (GM), Warren, Michigan 10. University of Michigan, Ann Arbor,, Michigan 11. Electricite de France (Jet Impingement test only), Chatou, S. & 0., France 12. English Electric Corp. (Jet Impingement test only), Leicester, Whetstone, England All the laboratories so far reporting, except Electricite de France, employed the vibratory type cavitation erosion apparatus. Therefore the results of Electricite de France, the only laboratory so far reporting which used the impact test, are separately presented, while those of the other laboratories are grouped together for comtparison.

3 The three standard materials are: 1. 316 Stainless Steel, supplied by the Jones & Laughlin Steel Corp. 2. 270 commercially pure nickel, supplied by the International Nickel Co. 3. 6061-T6511 aluminum alloy, supplied by the Aluminum Company of America. All of the samples from each of the three materials come from the same heat, have received the same processing and heat treating (and mostly have come from the same piece of bar stock). Therefore, the uniformity of the material itself is very good. In this report, the properties of the materials tested, the testing conditions at individual laboratories, and the test results are presented, as well as the wave forms front the transducers used by the different facilities. Photographs of the specimens at various stages of the tests are available but have been omitted from this preliminary report due to lack of time. They will be included in a final version. So far, only three materials have been included in the program, although it is hoped that the project will eventually bi expanded to cover additional materials. II. MATERIAL PROPERTIES The properties of the materials tested were determined by the following laboratories: 1. Worthington corp., Harrison, N. J., supplied the tensile test data. 2. NASA Lewis Center supplied the metallographic tests and the hardness test data. In addition they measured the chemical compositions which agree closely with information supplied by

4 the vendors. Both are listed in Table I. 3. Oak Ridge National Laboratory supplied the Charpy Impact test data. 4. The University of Michigan supplied the density data. It also conducted hardness tests which agreed closely with those supplied by NASA. Table 1 lists all these material properties. 5. Although at one point it had been thought desirable to have each laboratory heat treat the specimens after fabrication to remove cold work, it was later decided that this was impractical (see Appendix). However, Electricite de France did anneal the nickel and stainless steel specimens after fabrication and tested both annealed and unannealed specimens. As shown in Figs. 20, 21 and 22, there was considerable difference in damage results. III. TESTING CONDITIONS AT INDIVIDUAL LABOIRATOR-iS The pertinent test parameters include frequency, amplitude, and wave form of the transducer; roughness and diameter of specimen surface; pHt value of water, air content and temperature of water; and barometric pressure. All the laboratories used the conventional flat buttons except CIT which used rimmed specimens. These diata are collected and shown in Table 2. The wave forms available are reproduced as shoin in Figs. 1-3 (ionsanto's wave form, as stated in their report, "appears sinusoidal to eyes through microscope"). The following laboratories have so far reported results: 1. National Engineering Laboratory, East Kilbride, Glasgow, Scotland 2. NASA Lewis Center, Cleveland, Ohio 3. University of Minnesota,.Minneapolis, Minnesota /4. M onsanto Chemical Co mpany, St. Louis, Missouri 5. California Institute of Technology, Pasadena, California 6. Naval Applied Science Laboratory, Brooklyn, New York

C 7*- Hydronaut ics Inc. Laurel, -: II r 1id 8. University of Michigan, Ann Arbor, Michigan 9. Electricite de France, Chatou, S. & 0., France

6 TA i L I, M a eat r ial Properties jI 1 606 1-T6 5 1 [ 316 SS 2% Ni Al Alloy C 0.05 Mn 1.62 Ni 99.9 lin. Mg 0.8-1.2 Chemical Ni 13.03 Cr 17.45 Si 0.4-0.8 Chemical Composition (o) fo 2.72 Co,.1 Cr 0.15-0.35 Provided!Cu 0.21 s 0.027 Cu 0.15-0.40 by Supplier P 0.024 i0.66 Al Bal. Nominal composition range. Cr 1S Ni 13 Ni 99.98 Mg.O0 Mo 2.5 En 1.6 Si 0.6 Chemical Fe 3a 1,. Cu 0.25 Composition (') F (quoted Cr 0.25 bv NASA IAl A Bal. Tensile (psi) 81,250 48,750 47,260 Strength (Newton/m2) 560x106 336x106 328x106 0.27 Yield (psi) 31,310 8,000 40,680 Strength (Newton/ir2) 216x106 55.xi106? C81 106 Llon(ation (-) 69.0 61, 2.5 Reduction of Area (7o) 76.9 91.5 44.0 Hlardness (Rockwell-B) 74.8 24.9 60.1 Charpy Impact (Ft-Lb) 136.0 91.0 5.5 Strength (Joules) 184.1 i23.5 7.47 Density (Gm/cm3) 7.91 8*.94 _ 2.71 Metallographic data are shown on separate pages as Figs. 23, 24, & 25.

TABLE 2-A Testing Conditions for Vibratory Facilities LAB NEL MINN NASA MONSANTO CIT NASL U of M Hydronaut&ic Condition__________ Frequency 20.0 6.0 25.5 20.0 15.C 13.0 20.0 14.2 (kc/s) Amplitude (mril 2.0 4.0 1.75 2.0 2.0 1.85 2.0 1.5....(m) 5.08x10'5 10.16x105 4.445x10-5 5.08x10'5 5.08x105 4.7x05 5.08x105 1.588x105 Specimen (in).625.625.563.500.625.625.547.625 -2 -2 -2 -2 -2 -2 Diarreter (r5) i.58\iC-2 l.5~x1 1I035xl 19.27xi0' 1.58%xO t =.5x1O 1.3S9x10 1.58 xiC, lemp. (OF) 75+ 1 75-1 75+1 75+1 75+1 75+1 75+1 75+1 V,:ater (~C) 23,9.+_556 23.9+.556 23.9..55656 23.9+.556 23.9+. 23.566 23.9.556 23.955 Pressure (ir, Hg) 29.06 29.27 29.17 30.07 29.25 29.25 29.57 Above Water Surface (Newton/ 98.4x103 99.05x103 98.7x103 101.75xi03 93.98x103 98.98x103 101.08xl03 pH Value ofC 4.2/5.6 6.9/7.5 5.5 8.4 6.25 6.8 7.18 7.2 water'Air content (Ml/1)11.9/13.3 16.85 4/16 9.03/9.73 12. of (satur Water % ation) 68.5/76.5 97* 23/92 52/56 73.7 Specimen Al 12 Al 27 Surface 23-30 3-4 0 i 8 32 Ni 15 32 Roughness () SS 6 SS 18 * Initial Value

TABLE 2-B TLsting Conditions for Impingement Facilities LAB Electricite de English Condition France Electric Jet Diameter (m).005 RPtA 2900 Diameter Disk (m) 0.6 Specimen Height (m) 1.5x10'2 Specimen Diameter (m) 1.8x10l' Linear Velocity of Target at Diameter 94 Corresponding to Jet Axis (m/s) Jet Velocity (m/s) 14 Resultant Velocity (m/s) 95 (V'+V t 2) J target _ ____ __ __ _ __ _ ___ Temp, (oC.) 15.5 Pressure Surrounding Jet pH value Air Content Specimen Surface Roughness

9 Details of their tests, which have not been possible to include heire, are given in their individual reports (1-9). IV. CAVITATION DAMAGE COMPARISONS 1. The raw data from the vibrating cavitation erosion tests on an accumulative weight loss and accumulative volume loss basis are grouped in Figs. 4-9 (Average values of 2 or 3 samples were used in those cases where an individual laboratory tested more than one sample of each rmaterial). 2. The accumulative mean depth of penetration (MDP) is calculatcd using the weight loss data and the equation: MDP-C.W mils, where W-the weight loss in milligrams C-a material constant given by C-1000 1 25.4 PA where P-density in nig/nm3 (-g/cm3) A-specimen area in mm2 The "C" values are listed in Table 3. 3. Mean Depth of Penetration Rate (MDPt{) These values are derived by multiplying the weight loss rate by "C", and they are shown in Figs. 13-15. "Smoothed" versions of these curves have been constructed from the accumulated "iDP curves, Fig. 10-12. These were constructed by simply taking the best straight line approximation to the data after the incubation period to display clearly the different rates involved on this basis. Hence, no fine detail of the rate curves is given by these figures (except in a few cases where the deviatio;~ from a straight line was very substantial). These "smootheid"

10 TABLE 3 Specimen Material 1 "C" Diameter (in) Density (g/cm3) S.S. 7.91.025 0.625 Ni 8.94.0223 S.S. 7.91 - - — 03-3 0.563 Ni 8.94.0274 | — I — ___ _ _Al 2.71.0907 S.S. 7.91.0330 0.547 Ni 8.94.0288. — _._ Al 1 2.71.0935 S.S. 7.91.03~ - 0.500 Ni 8.94.0348 _-___, AAl 2.71 _.115 The accumulated MDP plots are shown in Figs. 10-12.

1I plots of MDPR are shown in Figs. 13a-15a. 4. Plots of accumulated Mean Depth of Penetration which convert all data to estimated data if the amplitude were 2 mils, so that these results can be approximately campared on the basis of the same amplitude, are shown in Figs. 16-18. This was accomplished by assuming that MDP A An, and taking a mean value for n of 1.7. This mean value represents a rough average of the available data, since Hobbs asserted that the weight loss varied with the amplitude (10) to the 1.5 power, while Thiruvengadam indicated that it varied with the amplitude squared. The amplitude conversion factors for the data from the four laboratories which used amplitudes other than 2 mils are shown below; Lab. Amplitude (mils) Conversion Factor Minn. 4.0 0.308 NASL. 1.85 1.143 NASA 1.75 1.255 Hlydronautics 1.6 1.462 5. Comparison of frequency and IiDPR peaks. By taking peak values of the MDPR curves 4ind plotting these against frequency, the approximate effect of frequency can be shown (Fig. 19). By plotting the peak values from the smoothed MDPR plots against frequency, the three curves shown in Fig. 19a result. 6. The results of the impingement erosion damage from Electricite de France are shown in Figs. 20-22 on an accumulative weight loss basis. Their testing conditions are shown in Table 2-B. For comparison, the damage curves of the three materials have been plotted together (Fig. 22a).

V. DISCUSSION OF RESULTS From the results supplied by the laboratories reporting to date, there has been the expected broad agreement between the overall rankings of the three different materials, i.e., all the laboratories ranked stainless steel, nickel, and aluminum alloy in order of decreasing damage resistance. The jet impingement apparatus of Electricite de France showed the same result. When the test data for one material from different laboratories are plotted on the same graph, a very substantial spread is found. This is presumably due to the minor differences in testing equipment and parameters. In terms of smoothed rates, without any correction for amplitude (Fig. 13a, 14a, and 15a), the maximum difference for each material is approximately a factor of three. If the amplitude correction is made the overall spread in average damage rates is even greater, primarily because the high amplitude Minnesota data is dropped well below the others when its 4 mil amplitude is corrected to 2 mils while previously:t had been intermediate in the group (i.e., the amplitude correction.s apparently too great in this case). However, the amplitude correction reduces the factor between the other facilities to a factor of about two if the aluminum from the high frequency (25.5 kc) NASA unit (discussed later) is also ignored for the moment. Note that this overall grouping includes the rimmed CIT specimens whereas all others are the standard flat design.

13 On the basis of the same frequency and same amplitude of units, NEL, Monsanto, and U of M data should be comparable, but to the contrary, the damage rates of all three materials produced by NEL were the highest obtained (except for Al); those of Monsanto were always (without exception) the lowest; while those of U of M were midway in between the two extremes. However, from the information available, there are some differences in the test apparatus and water used by these laboratories. NEL used a magnetostrictive transducer and a stepped horn. While Monsanto and U of M used piezoelectric transducers and catenoidal horns. The air contents and the p1l values of the water also showed some variation. Figs. 19 & 19a attempt to indicate very roughly the influence of frequency. The peak MDPR values from Figs. 13-15 are plotted against frequency for each material from the actual MDPR as well as from the smoothed MDPR plots. From these curves it appears that there is little effect of frequency between 15 and 25 kc, except for aluminum, where the damage is almost doubled going from 20 to 25 kc. Hence, it is conceivable that such an effect may be real as a result of the following argument*. For higher frequencies there are presumably more bubbles collapsing on the surface, but these will tend to be bubbles of smaller maximum diameter, at least as the frequency becomes quite large. Thus for higher frequency there may be more blows bat their average intensity may be lower. Such an attack may be relatively ineffective against a material of high fatigue strength, perhaps greater than the stress induced by most of the bubbles, but highly effective against weaker materials. *First suggested to the authors by R. Cheesewright, Queen Mary College, University of Londor.

14 Thus the relative position of dLffcrtent llaterzials oa a scale of cavitation resistence may depend upon tie intensity of the blows. This appears to be illustrated by the present tests in that the damage factor between aluminum and nickel is about 4.3 at 20 kc and 6.8 at 25 kc (Fig. 19). It may also be concluded from the present results that no simple relation will predict the effect of frequency on damage. Figs. 20-22a show the impact test results from Electricite de France. It is interesting to note that their further annealing of the stainless steel and nickel specimens after fabrication has increased the slope of the weight loss vs. time curve by a factor of about 2 for the stainless steel, but not affected the incubation period; for the nickel the effect upon the slope is much less, but the incubation period is reduced by annealing by a factor of more than 2.

1. Hobbs, J M., Personal Correspondence, National Engineering Laboratory, Glasgow, Lngland, November 1957. 2. Ripken, J. F., Personal Correspondence, University of M;innesota, Minneapolis, Minnesota, USA, N ovember 1967. 3. Freche, J. C., Personal Correspondence,'ASA Lewis Center, Dayton, Ohio, USA, November 1967. 4. Steinbrook, D. I), Personal Correspondence, Monsanto Company, St Louis, Missouri, USA, January 1968. 5. Plesset, M. S., "Cavitation Damnaae Measurements with;Nickel, Aluminum, and Stainless Steel for the AS F Round Robin", Report Nlo. 58-42, California Institute of Technology, Pasadena, California, USA, October 1967. 5. Lichtrran, J, Z*., Personal Correspondlence, U. S. Naval Applied Science Laboratory, Brooklyn, New York, USA, Decermber 1967. 7. Canavelis, R., "Comparison of the Resistance of Different Materiala With a Jet Impact Test Rig", 11C/061-230-9, Electricite de France, Chatou, France, November 1967. 8. Hammitt, F. G., Personal Correspondence, University of tiichigan, Ann Arbor, Michigan, USA, April 1968. 9. Rudy, S. L., "Cavitation Damage Tests for ASTMrl Round-Robin Program", Hlydronautics Inc., February 1968. 10. Hobbs, J.;., "Laboratory Evaluation of the Vibratory Cavitation Erosion Test", NEL Report No. 271, January 1967. 11. Thiruvengadam, A., "On Testing Materials for Cavitation Damage Resistance", Journal of Ship Research, Vol. 8, No. 3, Pages 3956, December 1964. 15

AMERICAN SOCIETY FoiR TESTING AND MATERIALS OA LAB ABROOKLYN, N. Y. 11251 t I P\ ^VICE-CHAIRMAN: F. G. HAMMITT, tJNIVERSI1Y OF MICHIGAN, DEPT. Of NUCLEAR ENGINEE RING, AUTOMOTIVE LA B.. ANN ARBOOKLYN. MICH. 48103 SECRETARY: S. W. DOROFF, OFFICE OF NAVAL RESEARCH, CODE 4311. WASHINGTON, D. C. 20360 Addretss reply! to - This is to invite your laboratory to participate in a round-robin cavitation damage test program using vibratory cavitation test facilities. While it is expected that eventually various metallic and non-metallic materials will be included, it is planned to start with only three: a. Aluminum type 6061-T-58 (Alcoa designation) b. Stainless Steel Type 316 (annealed) c. Pure Nickel, Type 270, annealed (International Nickel Company) It is presently planned that your laboratory will be supplied at least 4-inch lengths bar stock, with a diameter of at least 5/8 inch, of these materials, from which you will fabricate at least two of your own standard specimens, so that two tests can be run on each material by each laboratory. The specimen surface to be cavitated should be a ground finish (32 micro inch rms). For each material room temperature stress-strain curve and hardness will be measured and will be available to all participants. The residue of bar stock of each material will be maintained in a "materials bank" in the writer's laboratory to be available for later checks if desired. Each participating laboratory should anneal the stainless steel and nickel materials after specimen fabrication (but not the aluminum alloy) to be sure that no non-uniform cold work is induced in the specimen by the fabrication process. Standard annealing specifications for these materials will be furnished to the participating laboratories.* While it is planned that each participating laboratory should conduct the tests In a manner which they consider suitable, the following standard test specifications must be followed to eliminate the effect of unnecessary variables. a. Test Fluid-Distilled (or deionized) water at 75~F + 2~F, atmospheric * It was later decided (meeting of May 11, 1967) that this step would be omitted, and it is so recorded in the minutes of that meeting.

-2pressure (which should be measured)* b. At least 5 weight loss vs. duration points for each test. The spacing of these points is to be as considered appropriate by the participating laboratory. c. If at all possible, two specimens per material should be tested. We hope that this first series of tests can be completed and reported within six months of receipt of materials. All results obtained from the roundrobin program will be made available to all participating laboratories. Each participating laboratory must furnish the following information, in addition to the weight loss vs. duration points. a. Brief description, identification or illustration of apparatus (transducer, horn, generator, specimen design). b. Frequency (kcps). c. Double amplitude (inches). Wbe welcome your comments on the suitablity of these specifications. We are also enclosing a copy of a brief report prepared by A. Thiruvengadam of llydronautics, Inc., which describes presently available information on the performance of the high frequency (20kc/s) devices in common use today. I would also like to call to your attention "Accelerated-Cavitation Research" by W. J. Rheingans, Trans. ASME, July 1950, pp. 705-724, which presents similar information for the 6500 cps "standard ASME" magnetostriction device. May we please hear from you in regard to your participation in the proposed "round-robin" test program? Sincerely yours, Frederick G. Hamnnitt Professor Chairman Sub-Ccmittee I FGi: sc Enclosure

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3.16 Stainless Steel (18 Cr, 13 Ni, 2.5 Mo, 1.6 Mn, Bal. Fe) i~.~..-~.....'. / 25OX Etchant: 30 ml HC1, 30 ml Glycerine 10 ml HN03 + Electrolytic Grain Size: No. 4* (8 grains/square inch at 1OOX)''-. /.''~,.'"',.~..,.,,(..:_'I t F~* 9 "t,~~~~~~~~~~~,;** (8 grains/square inch at 100X)

Ni-270 (99.98% Ni)... (250 X) Etchant: 92% HCL, 5% H2S04, 3 HN03 Grain Size: Two different grain sizes: Approx. 60% Grain size 0* (1/2 grain/square inch at 10OX) Approx. 4(P0/ Grain size 2* (2 grains/square inch at 100X) *ASTM Austenite Grain Size Standard Measured by use of Grain size measuring eyepiece, and comparison of 10OX photomicrograph with ASTM standard grain size charts.

(H-/Wi 2 1: 6061-T6511 Aluminum (1.0%/ Mg, 0.6% Si, 0.25% Cu, 0.25% Cr, Bal Al) *-. C * *;.' t *'',;:tchant:.... e,. ml -N O'.'; t'v - - 4.~ -, * J X w, * ^ *'' e <*.' _ " ". ^ ~ *;,.' _.,, / * -., A O *'''. *,' **.' I s.A. % S 5,., 5, * r t *.. i'..5'' Etchant: 30 ml Glycerine, 20 mn HNO3 10 ml HF No grain boundaries visible.