Experimental and numerical investigations of sliding wear behaviour of an Fe-based alloy for PWR wear resistance applications

The excellent wear and corrosion resistance of Co-based alloys make them desirable for tribological applications in the nuclear industry. However, neutron activation of the Co-based alloys leads to significant occupational radiation doses. An alternative Fe-based alloy called RR2450 was developed by Rolls-Royce plc to replace these alloys. This paper presents the first comprehensive study evaluating the sliding wear resistance of RR2450 alloy in representative PWR conditions. The sliding counterface of RR2450 balls was a Co-based alloy, Haynes 25 discs. Four tests were performed at temperatures up to 80 °C, and 12 tests were performed up to 200 °C. Results showed wear performance of RR2450 balls degraded at higher loads and temperatures, with temperature having a significant role. Microstructural investigation revealed voids and hard silicide phases, negatively impacting wear resistance. Nonetheless, the wear performance of RR2450 was similar to a Co-based alloy, a=Stellite 20, at nuclear reactor conditions. Two wear tests with uneven wear tracks were selected for 3D finite element analysis. The wear simulation procedure is based on Archard's wear equation and is implemented in a commercial FE package, ABAQUS. The FEA method was used to capture the wear on both surfaces, and was shown to predict nominal wear profiles. These comparisons with experiments show that the FEA results can provide representative wear profiles when wear depths and widths are asymmetrical and irregular.