Microstructural Insights into Solid Particle Erosion in a High-Chromium Cast Iron

Solid particle erosion (SPE) significantly limits the service life of High-Chromium Cast Irons (HCCIs), widely used in power generation and mining industries. This study investigates how microstructural features influence the erosion resistance of a Fe-Cr-C cast iron, focusing on the interplay between particle kinetic energy and carbide features, i.e., carbide volume fraction (CVF). Erosion tests, conducted per ASTM G76 standards, revealed that substrates with similar CVFs exhibited varying damage levels, even at consistent particle kinetic energies. The findings underscored that impact conditions have a greater influence on erosion resistance than CVF alone, emphasizing the critical role of carbide morphology and distribution in mitigating damage. This work provides valuable insights for optimizing HCCIs to enhance material performance and durability in demanding erosive environments by tailoring carbide distribution to specific operational conditions.