daohang fenxiangbox searchbox qikanlogonew daohangnew searchboxnew navrightzone footerzone paper
中
Home > Journals > Chinese Journal of Rare Metals
Next Article ›

Research Progress on Erosive Wear of Alloy Impellers AITranslate

Yaxiong Wang1; Haoran Lin1; Jinbo Cai1; Kai Ou1; Xuezhi Zhang2; Shutan Niu2; Minghui Ma3;
1.School of Mechanical Engineering and Automation，Fuzhou University，Fuzhou 350108，China
2.Hebei Kingston Technology Co.，Ltd.，Xinji 052360，China
3.CATARC New Energy Vehicle Test Center （Tianjin）Co.，Ltd. Tianjin 300300，China
AITranslate
Publisher: Youke Publishing Co., Ltd
Share Citation Information Add to Favorites Download PDF

    Scan to share on WeChat or Moments

Use WeChat scan.
Share with WeChat friends or Moments

Abstract AITranslate

Alloy impellers are widely used in compressors and turbines in the fields of energy and power engineering and chemical industry. Their performance and life directly affect the efficient operation and reliability of mechanical systems. However，in the complicated operation conditions，solid particles and/or droplets carried by high-velocity fluids continuously impact the impellers，resulting in erosion and wear. Over time，this causes material spalling，microcrack propagation，and geometric deformation. As the damage accumulates，it ultimately leads to degradation of aerodynamic capability and even sudden failure. In this paper，the research progress on erosion and wear of alloy impellers was systematically reviewed. Furthermore，it analyzed the mechanism and influencing factors of wear types，anti-erosion materials，and erosion and wear protection measures. In this way，the study aimed to provide a theoretical basis and technical reference for improving the corrosion resistance of impellers. The types and mechanisms of erosion wear could be divided into four categories： gas-solid erosion wear，liquid-solid erosion wear，droplet erosion wear，and cavitation wear. Gas-solid erosion and liquid-solid erosion were commonly found in industrial fluids containing solid particles. These phenomena eroded the surface of materials through micro-cutting，plastic deformation，and crack propagation mechanisms. Micro-cutting theory and deformation wear theory have explained the wear behavior under low-angle and high-angle impacts，respectively. Beyond these mechanisms，the secondary erosion theory had further incorporated the secondary energy distribution effect after particle breakage. The droplet erosion mainly occurred in high-speed，such as steam turbineblades，where the droplet impact caused microplastic deformation on the surface and forms cavities. Subsequently，these cavities gradually expanded into continuous grooves，and a process further aggravated by the water hammer effect and stress wave propagation. The formation and rebound of secondary water droplets further boosted the erosion. Cavitation wear results from the collapse of cavitation bubbles caused by sudden changes in fluid pressure. This process generated micro-jets and high temperature and high pressure that impacted the surface，inducing material fatigue，lattice dislocation，and punctate spalling. In particular，the wear showed a synergistic effect with droplets in centrifugal compressors. The erosion wear was influenced by a variety of factors，including impurity，material properties，and environmental parameters. For the impurity，particle shape，particle size，impact velocity，and impact angle had significant impacts on the wear process. Regarding material properties，surface hardness，toughness，yield strength，and modulus of elasticity affected erosion resistance. For example，Ti6Al4V alloy exhibited excellent resistance to droplet erosion due to its high hardness and toughness. Environmental parameters such as fluid viscosity，saturated vapor pressure，and surface roughness indirectly exacerbated cavitation damage by changing cavitation nucleus formation and collapse behavior. To extend the life of impeller，the research focused on substrate materials，surface coating，structural design，and surface strengthening. In terms of substrate selection，titanium alloys （such as Ti6Al4V）were widely used benefitting from their high strength and corrosion resistance. But the high brittleness limited the application in some scenarios. Cobalt-based alloys absorbed impact energy through the phase transformation of the face-centered cubic structure to the hexagonal densely packed structure. This principle enabled them to exhibit excellent droplet erosion resistance. For the surface coating，the WC-Co coating prepared by supersonic flame spraying （HVOF）had a good performance due to its high hardness and low porosity. However，the spraying temperature needed to be strictly controlled to avoid carbide decomposition. The microhardness of the Cr3C2-NiCr coating by plasma spray welding was 6.46 times that of the substrate，and the anti-abrasive wear performance was significantly improved. In comparison，the Ni60A coating prepared by arc spraying and laser cladding technique reduced the crack sensitivity and water erosion depth by 53.2%. This enhancement primarily resulted from refining the grain and introducing the TiB2+TiC eutectic structure. The impeller structure optimization inhibited erosion through strategies such as biomimetic design，gap structure and balanced holes. Drawing on the pectoral fin shape of humpback whales，the bionic design achieved blade leading edge optimization with consequent reductions in cavitation volume and shock wave intensity. The gap structure used the conductive characteristics and pressure self-equilibrium to inhibit cavitation. The cavitation incidence was reduced by optimizing the circumferential position of the equilibrium hole. In the surface strengthening process，the high-power diode laser （HPDL）method was used to generate α martensitic phase on the surface of titanium alloys. This phase transformation enhanced droplet erosion resistance by 2 times. Gas nitriding formed a TiN/Ti2N composite layer on the surface of Ti6Al4V，and the erosion resistance was increased by 80%-125%. Shot peening and cavitation blasting reduced erosion by up to 95% by introducing compressive residual stresses and reducing surface roughness. At present，most of the research focused on a single protection technique，while erosion and wear were often coupled by multiple mechanisms under actual working conditions. In the future，we can focus on combining a variety of optimization schemes to improve impeller erosion resistance. For instance，the gradient structure alloy impeller material design may be integrated with surface coating for synergistic effects. Additionally，the impeller structure optimization can be considered alongside surface strengthening treatment to address multiple failure modes. In this way，the impeller's erosion resistance can be comprehensively improved to meet the needs of long life and high performance of the impeller under complex working conditions.

KeyWords AITranslate

alloy impellers erosive wear droplet shock cavitation erosion surface hardening

［1］（陈海生， 谭春青. 叶轮机械内部流动研究进展［J］. 机械工程学报， 2007， （2）： 1.）

H S Chen， C Q Tan. Review of investigation into internal flow of turbomachinery［J］. Journal of Mechanical Engineering， 2007， （2）： 1.

［2］（王光存， 李剑峰， 贾秀杰， 李方义， 刘子武. 离心压缩机叶轮材料FV520B冲蚀规律和机理的研究［J］. 机械工程学报， 2014， 50（19）： 182.）

G C Wang， J F Li， X J Jia， F Y Li， Z W Liu. Study on erosion behavior and mechanism of impeller's material FV520B in centrifugal compressor［J］. Journal of Mechanical Engineering， 2014， 50（19）： 182.

［3］（刘子恩， 范明豪， 赵跃， 陈海鹏， 苏文， 马凤翔. 特高压变压器潜油泵的冲蚀磨损仿真［J］. 腐蚀与防护， 2024， 45（4）： 69.）

Z E Liu， M H Fan， Y Zhao， H P Chen， W Su， F X Ma. Erosion simulation of submersible pump in an ultra-high voltage transformer［J］. Corrosion & Protection， 2024， 45（4）： 69.

［4］（高强， 任亚雄， 张琰， 阎宏伟. 微水头水流能水轮机水动力性能研究［J］. 太阳能学报， 2022， 43（5）： 419.）

Q Gao， Y X Ren， T Zhang， H W Yan. Study on hydrodynamic performance of micro-head flow energy turbine［J］. Acta Energiae Solaris Sinica， 2022， 43（5）： 419.

［5］（姚梦佳， 李春福， 何俊波， 候宇. 抗冲蚀磨损涂层的研究进展［J］. 材料导报， 2015， 29（S2）： 283.）

M J Yao， C F Li， J B He， Y Hou. Research progress on erosion-resistant wear coatings［J］. Materials Review， 2015， 29（S2）： 283.

［6］Li C， Bin G F， Li J， Liu Z Z. Study on the erosive wear of the gas-solid flow of compressor blade in an aero-turboshaft engine based on the Finnie model［J］. Tribology International， 2021， 163： 107197.

［7］Swain B， Mantry S， Mohapatra S S， Mallick P， Behera A. Dependency of solid particle erosion behaviour of plasma sprayed NiTi coating on primary gas flow rate［J］. Applied Surface Science Advances， 2025， 25： 100681.

［8］Mainardi V A， Cardoso R P， Brunatto S F， Scheuer C J. Slurry and liquid impingement erosion behavior of low-temperature plasma carburized AISI 420 martensitic stainless steel［J］. Surface & Coatings Technology， 2024， 477： 130390.

［9］Mondal J， Das K， Das S. The effect of microstructure and mechanical properties on the slurry erosion behavior of carbide-free bainitic and martensitic steel［J］. Wear， 2022， 504-505： 204422.

［10］（王健， 杜国正， 张永， 武政， 高靖， 苏力德. 运行状态下风力机叶片涂层沙蚀磨损研究［J］. 材料导报， 2021， 35（2B）： 04177.）

J Wang， G Z Du， Y Zhang， Z Wu， J Gao， L D Su. Research on sand erosion wear of wind turbine blade coating in operation state［J］. Materials Review， 2021， 35（2B）： 04177.

［11］Singh G， Jain P， Gill H S. Tribo-erosion analysis of HVOF colmonoy-88-coated pump impeller steel in coal ash particle slurries［J］. Journal of Tribology-Transactions of The Asme， 2024， 146（8）： 081702.

［12］（刘延鑫， 王旱祥， 汪润涛， 晁明伟， 张震宁， 黄海春， 马振勇. 电动潜油离心泵叶轮冲蚀磨损研究［J］. 中国石油大学（自然科学版）， 2017， 41（4）： 155.）

Y X Liu， H X Wang， R T Wang， M W Chao， Z N Zhang， H C Huang， Z Y Ma. Study on erosive wear of electric submersible pump's impeller［J］. Journal of China University of Petroleum （Edition of Natrual Science）， 2017， 41（4）： 155.

［13］Zhao R J， Zhao Y L， Zhang D S， Li Y， Geng L L. Numerical investigation of the characteristics of erosion in a centrifugal pump for transporting dilute particle-laden flows［J］. Journal of Marine Science and Engineering， 2021， 9（9）： 961.

［14］Hong B Y， Li Y B， Li X P， Li G， Huang A D， Ji S P， Li W D， Gong J， Guo J. Experimental investigation of erosion rate for gas-solid two-phase flow in 304 stainless/L245 carbon steel［J］. Petroleum Science， 2022， 19（3）： 1347.

［15］Mahdipoor M S， Kevorkov D， Jedrzejowski P， Medraj M. Water droplet erosion mechanism of nearly fully-lamellar gamma TiAl alloy［J］. Materials & Design， 2016， 89： 1095.

［16］Di J， Wang S S， Yan X J， Cai L X， Xie Y H. Experimental investigation on effect of surface strengthening process and roughness on water droplet erosion behavior in turbomachinery［J］. Tribology International， 2020， 153： 106647.

［17］Yang Y X， He M Q， Yu P， Kan C B， Wang X P， Yu X C， Chen X Y， Tao S L， Zhao C， Duan J B， An J Q， Sun Z Y. Investigation on critical erosion of gas production channel for sand carrying during injection and production process in gas storage［J］. Geoenergy Science and Engineering， 2024， 239： 212945.

［18］Luiset B， Sanchette F， Billard A， Schuster D. Mechanisms of stainless steels erosion by water droplets［J］. Wear， 2013， 303（1-2）： 459.

［19］Li D J， Jiang P， Sun F， Yuan X H， Zhang J P， Cao X Y. Water-droplet erosion behavior of high-velocity oxygen-fuel-sprayed coatings for steam turbine blades［J］. Corrosion Reviews， 2022， 40： 39.

［20］Rani P， Agrawal A K. SEM and EDX analysis of erosion products formed on steam turbine blade［J］. Materials at High Temperatures， 2023， 40（5）： 436.

［21］（潘家成， 徐亮， 高建民， 赵世全， 漆小兵， 王维. 轴向间距对二次水滴运动特性及沉积规律的影响［J］. 西安交通大学学报 （自然科学版）， 2012， 46（7）： 1.）

J C Pan， L Xu， J M Gao， S Q Zhao， X B Qi， W Wang. Influence of axial clearance on movement characteristic and deposition of secondary droplets［J］. Journal of Xi'an Jiaotong University （Natural Science Edition）， 2012， 46（7）： 1.

［22］（王晓墨， 黄素逸， 龙研. 波形板分离器中液滴二次携带碰壁模型［J］. 华中科技大学学报 （自然科学版）， 2003， 31（8）： 41.）

X M Wang， S Y Huang， Y Long. The model of secondary droplets in the steam-water separator with wave-shape vanes［J］. Journal of Huazhong University of Science and Technology （Natural Science Edition）， 2003， 31（8）： 41.

［23］（张峰. 汽轮机不同工况下低压缸末两级内水滴运动特性分析［J］. 汽轮机技术， 2022， 64（6）： 456.）

F Zhang. Analysis of water droplet motion characteristics at the end of low-pressure cylinder under different working conditions［J］. Steam Turbine Technology， 2022，64（6）： 456.

［24］Ahmad M， Schatz M， Casey M V. Experimental investigation of droplet size influence on low pressure steam turbine blade erosion［J］. Wear， 2013， 303： 83.

［25］（薛翔， 李勇， 刘福广， 黄其洲， 刘刚. 水滴特征对汽轮机叶片司太立合金水蚀的影响［J］. 热力发电， 2022， 51（7）： 116.）

X Xue， Y Li， F G Liu， Q Z Huang， G Liu. Effect of water droplet characteristics on water erosion of stellite alloy for steam turbine blades［J］. Thermal Power Generation， 2022， 51（7）： 116.

［26］Ahmad M， Casey M， Sürken N. Experimental assessment of droplet impact erosion resistance of steam turbine blade materials［J］. Wear， 2009， 267（9-10）： 1605.

［27］Oka Y I， Mihara S， Miyata H. Effective parameters for erosion caused by water droplet impingement and applications to surface treatment technology［J］. Wear， 2007， 263： 386.

［28］（邸娟， 王顺森， 蒋希航， 颜晓江， 周伟. 透平末级叶片材料抗水蚀特性的数值研究［J］. 西安交通大学学报， 2021， 55（2）： 38.）

J Di， S S Wang， X H Jiang， X J Yan， W Zhou. Numerical research on water erosion resistance characteristics of the substrate material of last stage blades in steam turbine［J］. Journal of Xi'an Jiaotong University， 2021， 55（2）： 38.

［29］Kirols H S， Kevorkov D， Uihlein A， Medra M. Water droplet erosion of stainless steel steam turbine blades［J］. Materials Research Express， 2017， 4： 8.

［30］Chidambaram P K， Kim H D. A numerical study on the water droplet erosion of blade surfaces［J］. Computers & Fluids， 2018， 164： 125.

［31］Kirols H S， Kevorkov D， Uihlein A， Medraj M. The effect of initial surface roughness on water droplet erosion behaviour［J］. Wear， 2015， 342： 198.

［32］Kumar P， Singal S K， Gohil P P. A technical review on combined effect of cavitation and silt erosion on Francis turbine［J］. Renewable and Sustainable Energy Reviews， 2024， 190（PB）： 114096.

［33］Liu Y C， Chu X， Yang G， Weigand B. Simulation and analytical modeling of high-speed droplet impact onto a surface［J］. Physics of Fluids， 2024， 36（1）： 012137.

［34］Peng K W， Tian S C， Li G S， Huang Z W， Yang R Y， Guo Z Q. Bubble dynamics characteristics and influencing factors on the cavitation collapse intensity for self-resonating cavitating jets［J］. Petroleum Exploration and Development， 2018， 45（2）： 343.

［35］Kondo T， Ando K. One-way-coupling simulation of cavitation accompanied by high-speed droplet impact［J］. Physics of fluids， 2016， 28（3）： 033303.

［36］Osman O O， Ahmed S M. Understanding surface morphology changes in stainless steel through stepwise cavitation erosion： a comprehensive study［J］. Engineering Failure Analysis， 2025， 167（PB）： 109017.

［37］Krella A， Marchewicz A. Effect of mechanical properties of CrN/CrCN coatings and uncoated 1.402 stainless steel on the evolution of degradation and surface roughness in cavitation erosion［J］. Tribology International， 2023， 177： 107991.

［38］Yao C L， He S S， Lee K Y， Shin K Y， Shim D. Microstructural transformation and corrosion–cavitation behavior of ultrasonic nanocrystal surface modified nickel aluminum bronze （NAB）［J］. Materials Today Communications， 2024， 40： 109697.

［39］da Silva F J， Marinho R R， Paes M T P， Franco S D. Cavitation erosion behavior of ion-nitrided 34 CrAlNi 7 steel with different microstructures［J］. Wear， 2013， 304（1-2）： 183.

［40］Wang Y J， Hao E K， Zhao X Q， Xue Y， An Y L， Zhou H D. Effect of microstructure evolution of Ti6Al4V alloy on its cavitation erosion and corrosion resistance in artificial seawater［J］. Journal of Materials Science & Technology， 2022， 100： 169.

［41］Nikolaos K， Phoevos K， Manolis G. Modelling cavitation during drop impact on solid surfaces［J］. Advances in Colloid and Interface Science， 2018， 260： 46.

［42］Örley F， Pasquariello V， Hickel S， Adams N A. Cut-element based immersed boundary method for moving geometries in compressible liquid flows with cavitation［J］. Journal of Computational Physics， 2015， 283： 1.

［43］Ezzatneshan E， Akbari A. Dynamics of cavitation bubble collapse in isothermal and cryogenic fluids： influence of condensable and non-condensable gases［J］. International Journal of Thermal Sciences， 2025， 211： 109710.

［44］Marzbali M， Yeganehdoust F， Ibrahim M E， Tarasi F， Jadidi M. Liquid-solid impact mechanism， liquid impingement erosion， and erosion-resistant surface engineering： a review［J］. Coatings， 2023， 13（3）： 577.

［45］Abedini M， Lozano C L D A Y， Kostka A， Hanke S. Influence of surface finishing by grinding on the cavitation erosion resistance of 316L and NiAl-bronze［J］. Wear， 2024， 554： 205432.

［46］Marzbali M， Yeganehdoust F， Ibrahim M E， Tarasi F， Jadidi M. Liquid-solid impact mechanism， liquid impingement erosion， and erosion-resistant surface engineering： a review［J］. Coatings， 2023， 13（3）： 577.

［47］Matsukawa C， Hayashi S， Yakuwa H， Kishikawa T， Narita T， Ukai S. High-temperature carburization behaviour of HASTELLOY X in CH4 gas［J］. Corrosion Science， 2011， 53（10）： 3131.

［48］Mahdipoor M， Kirols H， Kevorkov D， Jedrzejowski P. Influence of impact speed on water droplet erosion of TiAl compared with Ti6Al4V［J］. Scientific Reports， 2015， 5： 14182.

［49］Onur U， Sabri Ç K， Emin K. A systematic study into the cavitation erosion test for marine propeller materials by cavitating jet technique［J］. Ocean Engineering， 2023， 284： 115252.

［50］Di J， Wang S S， Yan X J， Jiang X H， Lian J Y， Zhang Z Y， Xie Y H. Experimental research on water droplet erosion resistance characteristics of turbine blade substrate and strengthened layers materials［J］. Materials， 2020， 13（19）： 4286.

［51］Ahmad M， Schatz M， Casey M V. An empirical approach to predict droplet impact erosion in low-pressure stages of steam turbines［J］. Wear， 2018， 402–403： 57.

［52］Mann B S， Arya V， Joshi P. Advanced high-velocity oxygen-fuel coating and candidate materials for protecting LP steam turbine blades against droplet erosion［J］. Journal of Materials Engineering and Performance， 2005， 14（4）： 487.

［53］Tarasi F， Mahdipoor M S， Dolatabadi A， Medraj M. HVOF and HVAF coatings of agglomerated tungsten carbide-cobalt powders for water droplet erosion application［J］. Journal of Thermal Spray Technology， 2016， 25（8）： 1711.

［54］（李太江， 刘庆伏， 李巍， 候庆洲. 汽轮机动叶片水蚀防护技术研究及应用［J］. 热加工工艺， 2011， 40（16）： 109.）

T J Li， Q F Liu， W Li， Q Z Hou. Study on protection techniques for last stage blades in steam turbine from water erosion and its application［J］. Hot Working Technology， 2011， 40（16）： 109.

［55］Mann B S， Arya V， Pant B K. Enhanced erosion protection of TWAS coated Ti6Al4V alloy using boride bond coat and subsequent laser treatment［J］. Journal of Materials Engineering and Performance， 2011， 20（6）： 932.

［56］（章友谊. 汽轮机叶片钢超音速火焰喷涂层和等离子喷焊层性能研究［J］. 表面技术， 2020， 49（10）： 99.）

Y Y Zhang. Performance of supersonic flame spray coating and plasma spray welding layer for turbine blade steel［J］. Surface Technology， 2020， 49（10）： 99.

［57］Zhang Z Y， Zhang D， Xie Y H. Experimental study on water droplet erosion resistance of coatings （Ni60 and WC-17Co） sprayed by APS and HVOF［J］. Wear， 2019， 432： 202950.

［58］Liao X J， Luo X T， Zhang L， Chen X， Sun Y Q， Li C X， Yang G J， Li C J. Mo-alloyed stainless steel coating with improved cavitation erosion resistance by plasma spraying a specially designed core-shell-structured powder［J］. Wear， 2023， 528： 204961.

［59］Ding X， Cheng X D， Yuan C Q， Shi J， Ding Z X. Structure of micro-nano WC-10Co4Cr coating and cavitation erosion resistance in NaCl solution［J］. Chinese Journal of Mechanical Engineering， 2017， 30（5）： 1239.

［60］Qin C P， Zheng Y G， Wei R. Cavitation erosion behavior of nanocomposite Ti-Si-C-N and Ti/Ti-Si-C-N coatings deposited on 2Cr13 stainless steel using a plasma enhanced magnetron sputtering process［J］. Surface & Coatings Technology， 2010， 204（21）： 3530.

［61］Lu H Y， Li Y L， Li F Y， Li J F， Wang L M， Ran X J， Li Z， Kong L. Erosion wear behavior of NiCr+Cr3C2-NiCr coating under multi-impact angle and novel coating structure design［J］. Journal of Materials Research and Technology-JMR& T， 2021， 14： 3123.

［62］（唐世延， 李太江， 李巍， 李勇， 杨二娟， 李聚涛. 超音速火焰喷涂抗水蚀涂层应用于核电汽轮机叶片的可行性分析［J］. 材料保护， 2016， 49（2）： 58.）

S Y Tang， T J Li， W Li， Y Li， E J Yang， J T Li. Feasibility analysis for application of water-erosion resistant coatings on steam turbine blade in nuclear power plant［J］. Materials Protection， 2016， 49（2）： 58.

［63］Mahdipoor M S， Tarasi F， Moreau C， Dolatabadi A， Medraj M. HVOF sprayed coatings of nano-agglomerated tungsten-carbide/cobalt powders for water droplet erosion application［J］. Wear， 2015， 330： 338.

［64］（张瑞珠， 李静瑞， 严大考， 赵元元. 水泵叶轮表面电火花熔覆WC-8Co耐磨涂层的机械性能研究［J］. 稀有金属材料与工程， 2015， 44（7）： 1587.）

R Z Zhang， J R Li， D K Yan， Y Y Zhao. Mechanical properties of WC-8Co wear-resistant coating on pump impellers surface by electro-spark［J］. Rare Metal Materials and Engineering， 2015， 44（7）： 1587.

［65］Cui C， Wu M P， He R， Gong Y L， Jie D D， Miao X J. Effect of CeO2 on the TiB2+TiC evolution and water droplet erosion resistance of laser-clad Ni60A coatings［J］. Proceedings of The Institution of Mechanical Engineers Part L-Journal of Materials-Design and Applications， 2023， 237（2）： 353.

［66］Oka Y I， Hayashi H. Evaluation of erosion resistance for metal-ceramic composites and cermets using a water-jet testing apparatus［J］. Wear， 271（9）： 1397.

［67］Azar P T G， Yelkarasi C， Ürgen M. The role of droplets on the cavitation erosion damage of TiN coatings produced with cathodic arc physical vapor deposition［J］. Surface & Coatings Technology， 2017， 322： 211.

［68］Alwan H L， Makarov A V， Soboleva N N， Korobov Y S， Shumyakov V I， Lezhnin N V， Zavalishin V A. Using a procedure for estimating cavitation impact for analyzing the erosion resistance of cermet thermal sprayed coatings［J］. Russian Journal of Non-Ferrous Metals， 2022， 62（6）： 778.

［69］Singh V， Kumar A， Kaur S， Bansal A， Singla A K. Enhancing cavitation erosion resistance of VC+TiC coatings with PTFE in marine environments via lasso regression optimization［J］. Tribology International， 2024， 196： 109697.

［70］Li G Y， Ding X H， Wu Y B， Wang S R， Li D， Yu W J， Wang X Z， Zhu Y H， Guo Y T. Liquid-vapor two-phase flow in centrifugal pump： cavitation， mass transfer， and impeller structure optimization［J］. Vacuum， 2022， 201： 111102.

［71］Pei J， Yin T Y， Yuan S Q， Wang W J， Wang J B. Cavitation optimization for a centrifugal pump impeller by using orthogonal design of experiment［J］. Chinese Journal of Mechanical Engineering， 2017， 30（1）： 103.

［72］Dönmez A H， Yumurtaci Z， Kavurmacioğlu L. Cavitation performance enhancement of a centrifugal pump impeller based on Taguchi's orthogonal optimization［J］. Arabian Journal for Science and Engineering， 2024， （prepublish）： 1.

［73］Xin J C， Liu X Y， Liu F Y， Wang Y L， Tian Z T， Lu H W. Study on the influence of variable inlet guide vane slot on the aerodynamic performance in air storage centrifugal compressor［J］. Journal of Energy Storage， 2024， 90（PA）： 111907.

［74］Zhang J S， Xi W Q， Tang J X， Huang Z W. Exploring cavitation dynamics and noise reduction in hydraulic machinery with bionic leading edge impeller［J］. Physics of Fluids， 2024， 36（9）： 095133.

［75］Dolatabadi A M， Pour M S， Ajarostaghi S S M， Poncet S， Hulme-Smith C. Last stage stator blade profile improvement for a steam turbine under a non-equilibrium condensation condition： a CFD and cost-saving approach［J］. Alexandria Engineering Journal， 2023， 73： 27.

［76］Yao H， Zhou X. A pioneering method for reducing water droplet erosion［J］. Journal of Fluids Engineering， 2018， 140（6）： 061401.

［77］Sun S， Song P， Sun J J， Sun W Y. Cavitation suppression and design optimization in a cryogenic liquid turbine expander based on thermodynamic cavitation and entropy production analysis［J］. Journal of Fluids Engineering， 2023， 145（1）： 011201.

［78］Song P， Sun J J. Cryogenic cavitation mitigation in a liquid turbine expander of an air-separation unit through collaborative fine-tuned optimization of impeller and fairing cone geometries［J］. Energies， 2019， 13（1）： 50.

［79］Song P， Sun J J， Huo C J. Cavitating flow suppression for a two-phase liquefied natural gas expander through collaborative fine-turning design optimization of impeller and exducer geometric shape［J］. Journal of Fluids Engineering， 2020， 142（5）： 051401.

［80］Song P， Sun J J， Wang K. Swirling and cavitating flow suppression in a cryogenic liquid turbine expander through geometric optimization［J］. Proceedings of the Institution of Mechanical Engineers， Part A： Journal of Power and Energy， 2015， 229（6）： 628.

［81］Zhu B， Chen H X， Wei Q. Numerical and experimental investigation of cavitating characteristics in centrifugal pump with gap impeller［J］. International Journal of Turbo & Jet-Engines， 2014， 31（2）： 187.

［82］（潘家成， 徐亮， 高建民， 赵世全， 漆小兵， 王维. 轴向间距对二次水滴运动特性及沉积规律的影响［J］. 西安交通大学学报， 2012， 46（7）： 1.）

J C Pan， L Xu， J M Gao， S Q Zhao， X B Qi， W Wang. Effect of axial spacing on the motion characteristics and sedimentation law of secondary water droplets［J］. Journal of Xi'an Jiaotong University， 2012， 46（7）： 1.

［83］Ren Q N， Hu H X， Zheng Y G. Effect of surface microstructure spacing on the cavitation erosion process of stainless steel［J］. Wear， 2024， 558： 205542.

［84］（陈由翔， 陈子峰， 杨斌， 张荻， 谢永慧， 李一兴. 高速液滴撞击下叶片表面微结构防水蚀性能研究［J］. 西安交通大学学报， 2023， 57（5）： 68.）

Y X Chen， Z F Chen， B Yang， D Zhang， Y H Xie， Y X Li. Research on waterproof and corrosion properties of leaf surface microstructure under high-speed droplet impact［J］. Journal of Xi'an Jiaotong University， 2023， 57（5）： 68.

［85］Wang L， Xie J H， Wang P Z， Zhao G S， Huang B， Wu D Z. Analysis of the obstacle height's influence on partial cavitation flow based on the Lagrangian coherent structure［J］. International Journal of Multiphase Flow， 2024， 171： 104690.

［86］（赵国寿， 伍锐， 车邦祥， 曹琳琳， 吴大转. 基于障碍物的轴流泵叶片空化控制［J］. 浙江大学学报（工学版）， 2021， 55（4）： 742.）

G S Zhao， R Wu， B X Che， L L Cao， D Z Wu. Cavitation control of axial flow pump blades based on obstacles［J］. Journal of Zhejiang University （Engineering Science）， 2021， 55（4）： 742.

［87］Hosseini S A， Nakisa M， Lakzian E. Reducing the condensing flow effects on the steam turbine blades through modified design geometry［J］. Physics of Fluids， 2023， 35（9）： 095119.

［88］Zhang R H， Yun L C， Li J. The effect of impeller slot jet on centrifugal pump performance［J］. Journal of Hydrodynamics， 2019， 31（4）： 733.

［89］Cheng X R， Luo J H， Xiong B， Jiang B. Influence of the balance hole circumferential position on the cavitation performance of the semiopen impeller centrifugal pump［J］. Mathematical Problems in Engineering， 2021， 2021： 4472433.

［90］Cheng X R， Chang Z B， Jiang Y M. Study on the influence of the specific area of balance hole on cavitation performance of high-speed centrifugal pump［J］. Journal of Mechanical Science and Technology， 2020， 34（8）： 1.

［91］Mann B S， Arya V， Pant B K. Influence of laser power on the hardening of Ti6Al4V low-pressure steam turbine blade material for enhancing water droplet erosion resistance［J］. Journal of Materials Engineering and Performance， 2011， 20（2）： 213.

［92］Mann B S. Laser treatment of textured X20Cr13 stainless steel to improve water droplet erosion resistance of LPST blades and LP bypass valves［J］. Journal of Materials Engineering and Performance， 2013， 22（12）： 3699.

［93］（吴国龙， 王睿， 陈祥辉， 王晔， 文陈， 姚建华. TC4合金表面激光复合微弧氧化涂层制备及热腐蚀失效研究［J］. 稀有金属， 2024， 48（6）： 774.）

G L Wu， R Wang， X H Chen， Y Wang， C Wen， J H Yao. Preparation of laser-assisted micro-arc oxidation coating on TC4 alloy surface and thermal corrosionfailure study［J］. Chinese Journal of Rare Metals， 2024， 48（6）： 774.

［94］（陈炜， 王逸凡， 刘杰， 曹一枢， 白瑛， 陈春刚， 张小计. 复杂热冲压模具型面的激光熔覆强化及摩擦磨损控制技术［J］. 锻压技术， 2024， 49（3）： 186.）

W Chen， Y F Wang， J Liu， Y S Cao， Y Bai， C G Chen， X J Zhang. Laser cladding strengthening of complex hot stamping die surface and friction and wear control technology［J］. Forging & Stamping Technology， 2024， 49（3）： 186.

［95］Gong Y L， Cui C， Wu M P， Miao X J. The water droplet erosion resistance of Ni-based composite coating through laser cladding［J］. Materials Research Express， 2021， 8（9）： 096524.

［96］Kwok C T， Man H C， Cheng F T， Lo K H. Developments in laser-based surface engineering processes： with particular reference to protection against cavitation erosion［J］. Surface & Coatings Technology， 2016， 291： 189.

［97］（周骛， 蔡小舒， 吉肖. 叶片表面超亲水和超疏水特性对二次水滴形成影响的研究［J］. 动力工程学报， 2014， 34（4）： 292.）

W Zhou， X S Cai， X Ji. Influence of blade surface super-hydrophilic and super-hydrophobicproperty on formation of secondary droplets［J］. Journal of Chinese Society of Power Engineering， 2014， 34（4）： 292.

［98］Gonzalez-Pociño A， Alvarez-Antolin F， Asensio-Lozano J. Influence of thermal parameters related to destabilization treatments on erosive wear resistance and microstructural variation of white cast iron containing 18% Cr. application of design of experiments and rietveld structural analysis［J］. Materials， 2019， 12（19）： 3252.

［99］Sasaki H， Takeo F， Soyama H. Cavitation erosion resistance of the titanium alloy Ti-6Al-4V manufactured through additive manufacturing with various peening methods［J］. Wear， 2020， 462： 203518.

［100］（王俣豪， 乔柯， 张兵， 王快社， 王文， 孙琦. 冷喷摩擦复合增材制造制备ZrO2颗粒增强钛基复合材料组织与磨损性能［J］. 塑性工程学报， 2024， 31（2）： 105.）

Y H Wang， K Qiao， B Zhang， K S Wang， W Wang， Q Sun. Microstructure and tribological properties of ZrO2 particles reinforced titanium matrix composites prepared via cold spray-friction composite additive manufacturing［J］. Journal of Plasticity Engineering， 2024， 31（2）： 105.

［101］Grinspan A S， Gnanamoorthy R. Development of a novel oil cavitation jet peening system and cavitation jet erosion in aluminum alloy， AA 6063-T6［J］. Journal of Fluids Engineering-Transactions of the ASME， 2009， 131（6）： 061301.

［102］Du J Y， Li F Y， Li Y L， Wang L M， Lu H Y， Ran X J， Zhang X Y. Influences of plasma arc remelting on microstructure and service performance of Cr3C2-NiCr/NiCrAl composite coating［J］. Surface & Coatings Technology， 2019， 369： 16.

［103］（刘含笑， 刘凯， 王祥德， 薛婷婷， 郭飞， 吕东芹， 王巍. 电位滴定法测定铁中间合金中铁含量［J］. 分析试验室， 2024， 43（6）： 858.）

H X Liu， K Liu， X D Wang， T T Xue， F Guo， D Q Lv， W Wang. Determination of iron content in intermediate ferroalloy by automatic potentiometric titration method［J］. Chinese Journal of Analysis Laboratory， 2024， 43（6）： 858.

［104］Mandipoor M S， Kevorkov D， Jedrzejowski P， Medraj M. Water droplet erosion behaviour of gas nitrided Ti6Al4V［J］. Surface & Coatings Technology， 2016， 292： 78.

［105］Batory D， Szymanski W， Panjan M， Zabeida O. Plasma nitriding of Ti6A14V alloy for improved water erosion resistance［J］. Wear， 2017， 374： 120.

［106］Mednikov A F， Ryzhenkov A V， Brovka G M， Kachalin G V， Tkhabisimov A B， Zilova O S. Effect of stresses occurring under modifying 20Kh13 grade steel on the incubation period of water droplet impact erosion［J］. Thermal Engineering， 2022， 69（11）： 844.

［107］（韦敏康， 高峰， 高如高， 梁耀东， 罗增武. 井下充填料管道泵送阻力与输送参数优化研究［J］. 黄金， 2023， 44（1）： 12.）

M K Wei， F Gao， R G Gao， Y D Liang， Z W Luo. Optimization of pumping resistance and transportation parameters of down hole filling pipeline ［J］.Gold， 2023， 44（1）： 12.

Basic Information:

DOI：10.13373/j.cnki.cjrm.XY25040018

Chinese Library Classification Number:TG133+.4

Citation Information:

Alloy impellers are widely used in compressors and turbines in the fields of energy and power engineering and chemical industry. Their performance and life directly affect the efficient operation and reliability of mechanical systems. However，in the complicated operation conditions，solid particles and/or droplets carried by high-velocity fluids continuously impact the impellers，resulting in erosion and wear. Over time，this causes material spalling，microcrack propagation，and geometric deformation. As the damage accumulates，it ultimately leads to degradation of aerodynamic capability and even sudden failure. In this paper，the research progress on erosion and wear of alloy impellers was systematically reviewed. Furthermore，it analyzed the mechanism and influencing factors of wear types，anti-erosion materials，and erosion and wear protection measures. In this way，the study aimed to provide a theoretical basis and technical reference for improving the corrosion resistance of impellers. The types and mechanisms of erosion wear could be divided into four categories： gas-solid erosion wear，liquid-solid erosion wear，droplet erosion wear，and cavitation wear. Gas-solid erosion and liquid-solid erosion were commonly found in industrial fluids containing solid particles. These phenomena eroded the surface of materials through micro-cutting，plastic deformation，and crack propagation mechanisms. Micro-cutting theory and deformation wear theory have explained the wear behavior under low-angle and high-angle impacts，respectively. Beyond these mechanisms，the secondary erosion theory had further incorporated the secondary energy distribution effect after particle breakage. The droplet erosion mainly occurred in high-speed，such as steam turbineblades，where the droplet impact caused microplastic deformation on the surface and forms cavities. Subsequently，these cavities gradually expanded into continuous grooves，and a process further aggravated by the water hammer effect and stress wave propagation. The formation and rebound of secondary water droplets further boosted the erosion. Cavitation wear results from the collapse of cavitation bubbles caused by sudden changes in fluid pressure. This process generated micro-jets and high temperature and high pressure that impacted the surface，inducing material fatigue，lattice dislocation，and punctate spalling. In particular，the wear showed a synergistic effect with droplets in centrifugal compressors. The erosion wear was influenced by a variety of factors，including impurity，material properties，and environmental parameters. For the impurity，particle shape，particle size，impact velocity，and impact angle had significant impacts on the wear process. Regarding material properties，surface hardness，toughness，yield strength，and modulus of elasticity affected erosion resistance. For example，Ti6Al4V alloy exhibited excellent resistance to droplet erosion due to its high hardness and toughness. Environmental parameters such as fluid viscosity，saturated vapor pressure，and surface roughness indirectly exacerbated cavitation damage by changing cavitation nucleus formation and collapse behavior. To extend the life of impeller，the research focused on substrate materials，surface coating，structural design，and surface strengthening. In terms of substrate selection，titanium alloys （such as Ti6Al4V）were widely used benefitting from their high strength and corrosion resistance. But the high brittleness limited the application in some scenarios. Cobalt-based alloys absorbed impact energy through the phase transformation of the face-centered cubic structure to the hexagonal densely packed structure. This principle enabled them to exhibit excellent droplet erosion resistance. For the surface coating，the WC-Co coating prepared by supersonic flame spraying （HVOF）had a good performance due to its high hardness and low porosity. However，the spraying temperature needed to be strictly controlled to avoid carbide decomposition. The microhardness of the Cr3C2-NiCr coating by plasma spray welding was 6.46 times that of the substrate，and the anti-abrasive wear performance was significantly improved. In comparison，the Ni60A coating prepared by arc spraying and laser cladding technique reduced the crack sensitivity and water erosion depth by 53.2%. This enhancement primarily resulted from refining the grain and introducing the TiB2+TiC eutectic structure. The impeller structure optimization inhibited erosion through strategies such as biomimetic design，gap structure and balanced holes. Drawing on the pectoral fin shape of humpback whales，the bionic design achieved blade leading edge optimization with consequent reductions in cavitation volume and shock wave intensity. The gap structure used the conductive characteristics and pressure self-equilibrium to inhibit cavitation. The cavitation incidence was reduced by optimizing the circumferential position of the equilibrium hole. In the surface strengthening process，the high-power diode laser （HPDL）method was used to generate α martensitic phase on the surface of titanium alloys. This phase transformation enhanced droplet erosion resistance by 2 times. Gas nitriding formed a TiN/Ti2N composite layer on the surface of Ti6Al4V，and the erosion resistance was increased by 80%-125%. Shot peening and cavitation blasting reduced erosion by up to 95% by introducing compressive residual stresses and reducing surface roughness. At present，most of the research focused on a single protection technique，while erosion and wear were often coupled by multiple mechanisms under actual working conditions. In the future，we can focus on combining a variety of optimization schemes to improve impeller erosion resistance. For instance，the gradient structure alloy impeller material design may be integrated with surface coating for synergistic effects. Additionally，the impeller structure optimization can be considered alongside surface strengthening treatment to address multiple failure modes. In this way，the impeller's erosion resistance can be comprehensively improved to meet the needs of long life and high performance of the impeller under complex working conditions.

quote

GB/T 7714-2015 [1] Yaxiong Wang, Haoran Lin, Jinbo Cai, et al. Research Progress on Erosive Wear of Alloy Impellers[J]. Chinese Journal of Rare Metals, 2025, 49(9): 1435-1453. DOI:10.13373/j.cnki.cjrm.XY25040018.
MLA [1] Yaxiong Wang, et al., "Research Progress on Erosive Wear of Alloy Impellers." Chinese Journal of Rare Metals, vol. 49, no. 9, 2025, pp. 1435-1453, https://doi.org/10.13373/j.cnki.cjrm.XY25040018.
APA [1] Yaxiong Wang, Haoran Lin, Jinbo Cai, Kai Ou, Xuezhi Zhang, Shutan Niu, & Minghui Ma. (2025). Research Progress on Erosive Wear of Alloy Impellers. Chinese Journal of Rare Metals, 49(9), 1435-1453. https://doi.org/10.13373/j.cnki.cjrm.XY25040018
IEEE [1] Yaxiong Wang, Haoran Lin, Jinbo Cai, Kai Ou, Xuezhi Zhang, Shutan Niu, and Minghui Ma, "Research Progress on Erosive Wear of Alloy Impellers," Chinese Journal of Rare Metals, vol. 49, no. 9, pp. 1435-1453, 2025, doi: 10.13373/j.cnki.cjrm.XY25040018. keywords: {alloy impellers;erosive wear;droplet shock;cavitation erosion;surface hardening}