Meaning
Material removal caused by the high-velocity impact of liquid slurry containing suspended abrasive particles is a known wear mechanism in manufacturing equipment. In battery production, hydro abrasive erosion occurs in the mixing and coating systems where active material slurries are pumped. These highly viscous fluids contain hard particles that wear away steel pipes.
Wear Mechanism
Localized turbulence in the flowing slurry accelerates the loss of protective oxide layers on the internal surfaces of the pipeline. Once these layers are breached, hydro abrasive erosion continuously strips the underlying metal, leading to thinning of the pipe walls. The rate of wear depends on the angle of impact and the hardness of the suspended solids.
This erosion is particularly severe at elbows, T-joints, and where the cross-sectional area of the pipe changes abruptly.
Component Protection
Applying specialized coatings to the internal surfaces of the mixing vessel helps to maintain structural integrity. These barriers must resist hydro abrasive erosion while remaining chemically inert to the aggressive solvents used in slurry preparation. Tungsten carbide or silicon carbide inserts are often selected for high-wear areas like nozzle orifices.
System Failure
Contamination of the electrode slurry occurs when eroded metallic particles enter the mixture. These metal shavings can migrate to the separator during coating and cause internal short circuits. Thus, monitoring the rate of wear is important for maintaining high yield rates.
