journal article·2025-07-05Open access

Effect of Grain Size and Incidence Angle on Erosive Wear of Polyurea Coating

Justyna Sokolska, Piotr Sokolski

Applied Sciences· Volume 15· Issue 13

Abstract

This study investigated the erosive wear of a polyurea coating with a hardness of 95 ShA and a thickness of 3 mm applied to a 3 mm thick plate made of S235 steel. The process of erosive wear was carried out using a stream of compressed air containing abrasive grains of aluminum oxide (Al2O3). The erosive wear was studied using different incidence angles (45°, 60° and 90°) and erosive grain sizes. Thus, the effects of the incidence angle and erosive grain size on the erosive wear of the polyurea coating were analyzed. Erosive wear was determined as linear wear: the depth of the wear trace was measured using an optical profilometer. This study showed a non-linear correlation between erosive wear, incidence angle and erosive particle size. In addition, a qualitative study of the surface of the coating after a wear test was carried out using a scanning electron microscope, which made it possible to describe the mechanisms of erosive wear of the polyurea coating.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Erosion and Abrasive Machining · Mechanical Behavior of Composites · Materials Engineering and Processing

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

Department of Fundamentals of Machine Design and Mechatronic Systems, Faculty of Mechanical Engineering, Wroclaw University of Science and Technology, ul. I. Lukasiewicza 5, 50-371 Wroclaw, Poland

References (47)

Show source-provided references
1. Comparative Evaluation of Solid Particle Erosion Resistance in Milled Carbon Fiber-Reinforced Basalt Fiber Epoxy Composites: Impact of Abrasive Shape Variations10.1002/pc.28949 ↗
2. Milled Basalt Fibers as Reinforcement for Polyurea Composite Spray Coatings with Improved Thermomechanical Stability and Mechanical Performance10.14314/polimery.2020.3.3 ↗
3. Investigation of a Novel Hydraulic Tunnel Composite Lining with Polyurea Coating Interlayer10.1108/EC-01-2024-0011 ↗
4. Wang, Y., Ding, L., Lin, J., Qiu, X., Wu, C., Liu, C., Tian, Y., Zhang, R., Huang, W., and Ma, M. (2024). Recent Developments in Polyurea Research for Enhanced Impact Penetration Resistance and Blast Mitigation. Polymers, 16.10.3390/polym16030440 ↗
5. Investigation of Polyurea Coating Influence on Dynamic Mechanical Properties of Concrete10.1016/j.istruc.2024.107446 ↗
6. Shear Strength of Reinforced Concrete Columns Retrofitted by Glass Fiber Reinforced Polyurea10.28991/cej-2020-03091587 ↗
7. Toader, G., Diacon, A., Axinte, S.M., Mocanu, A., and Rusen, E. (2024). State-of-the-Art Polyurea Coatings: Synthesis Aspects, Structure–Properties Relationship, and Nanocomposites for Ballistic Protection Applications. Polymers, 16.10.3390/polym16040454 ↗
8. Polyurea-Coated Ceramic-Aluminum Composite Plates Subjected to Low Velocity Large Fragment Impact10.1016/j.mtcomm.2022.104501 ↗
9. Luo, J., Wang, T., Sim, C., and Li, Y. (2022). Mini-Review of Self-Healing Mechanism and Formulation Optimization of Polyurea Coating. Polymers, 14.10.3390/polym14142808 ↗
10. Ballistic Performance of Aluminum Alloy Plates with Polyurea Coatings for High-Speed Train Structures10.1016/j.compstruct.2024.118553 ↗
11. Polyurea: Evolution, Synthesis, Performance, Modification, and Future Directions10.1016/j.porgcoat.2025.109127 ↗
12. Characterisation of Polyurethane-Urea as Leading-Edge Erosion Resistant Materials of Wind Turbine Blades10.1088/1755-1315/1344/1/012015 ↗
13. Effects of Surface Preparation on the Adhesion of UV-Aged Polyurethane Coatings10.1016/j.ijadhadh.2022.103183 ↗
14. Sand Erosion of Polyurethane Coating Materials for CFRP at Elevated Temperature10.2320/matertrans.MT-Z2022002 ↗
15. The Study of the Tribological Properties under High Contact Pressure Conditions of TiN, TiC and TiCN Coatings Deposited by the Magnetron Sputtering Method on the AISI 304 Stainless Steel Substrate10.2478/msp-2022-0055 ↗
16. Micro-abrasive wear mechanisms of P/M AISI M2 steel with different surface treatments10.1016/j.surfcoat.2017.10.020 ↗
17. Abrasion wear of indefinite chill cast iron: Experimental and numerical approaches at multiple scales10.1016/j.wear.2025.205823 ↗
18. Mechanical behavior and abrasive mechanism mapping applied to micro-scratch tests on homogeneous and heterogeneous materials: FEM and experimental analyses10.1016/j.wear.2020.203240 ↗
19. Non-destructive erosive wear monitoring of multi-layer coatings using AI-enabled differential split ring resonator based system10.1038/s41467-023-40636-9 ↗
20. Finite element modeling of erosive wear10.1016/j.ijmachtools.2005.01.007 ↗
21. Neural network supported study on erosive wear performance analysis of Y2O3/WC-10Co4Cr HVOF coating10.1016/j.jksues.2021.12.005 ↗
22. Adhesion Phenomena in Bonded Joints10.1016/j.ijadhadh.2012.04.007 ↗
23. Mayer-Trzaskowska, P., Robakowska, M., Gierz, Ł., Pach, J., and Mazur, E. (2024). Observation of the Effect of Aging on the Structural Changes of Polyurethane/Polyurea Coatings. Polymers, 16.10.3390/polym16010023 ↗
24. Thermo-Mechanical Characterization of Polyurea Variants10.1007/s11043-020-09454-0 ↗
25. The Reasons for the Loss of Polyurea Coatings Adhesion to the Concrete Substrate in Chemically Aggressive Water Tanks10.1016/j.engfailanal.2022.106774 ↗
26. Peng, C., Ren, J., and Wang, Y. (2024). Degradation Behavior and Lifetime Prediction of Polyurea Anti-Seepage Coating for Concrete Lining in Water Conveyance Tunnels. Materials, 17.10.3390/ma17081782 ↗
27. Toolbox for Optimizing Anti-Erosion Protective Coatings of Wind Turbine Blades: Overview of Mechanisms and Technical Solutions10.1002/we.2378 ↗
28. Experimental study on the effect of hardness on the erosion resistance of coatings and rubber for hydropower applications10.1520/JTE20180775 ↗
29. Erosion and Heating of Polyurea under Cavitating Jets10.1016/j.wear.2018.08.019 ↗
30. The Development of High-Strength, Anticorrosive, and Strongly Adhesive Polyaspartate Polyurea Coating Suitable for Pipeline Spray Repairs10.1002/app.55668 ↗
31. Unveiling Carbon Fiber Reinforced Polyurea Composites Engineered through Vacuum Assisted Resin Transfer Molding: An In-Depth Analysis of Mechanical, Thermal, and Degradation Performance10.1021/acsaenm.3c00537 ↗
32. Remotely Fast Response Healing Crosslinked Polyurea Nanocomposites with Recyclability via Two-Step Method10.1016/j.compscitech.2022.109462 ↗
33. Epoxy/Polyurethane Nanocomposite Coatings for Anti-Erosion/Wear Applications: A Review10.1177/0021998320908299 ↗
34. Li, B., Zhang, Z., Wang, X., and Liu, X. (2019). Investigation on the Debonding Failure Model of Anchored Polyurea Coating under a High-Velocity Water Flow and Its Application. Sustainability, 11.10.3390/su11051261 ↗
35. Sokolska, J., and Ptak, A. (2024). Abrasive and Erosive Wear Behavior of Elastomeric Polyurethane Coatings: Effect of Grain Size. Coatings, 14.10.3390/coatings14121611 ↗
36. Abrasion test of flexible protective materials on hydraulic structures
37. Research on Application of Single Component Polyurea in Defect Treatment of Expansion Joints of Water Conveyance Structure
38. Influence of the Erodent Shape on the Erosion Behavior of Ductile and Brittle Materials10.1007/s11249-016-0800-x ↗
39. Luo, J., Meng, Y., Shao, T., and Zhao, Q. (2009). Erosion Behaviors of Elastic Polymer Coatings. Advanced Tribology, Springer.
40. Analysis of Polyurethane Top-Coat Destruction Influence on Erosion Kinetics of Polyurethane-Epoxy Coating System10.17531/ein.2019.1.12 ↗
41. An experimental study on the resistance of a polyurea-sprayed structure to low-speed drop hammer impact10.1016/j.conbuildmat.2024.136915 ↗
42. Study on mechanical properties aging of spray pure polyurea for hydraulic concrete protection
43. (2025, May 11). KOS Materiały Ścierne. Available online: www.korund.pl.
44. Molecular dynamics simulations and hygrothermal aging of polyurea–poss nanocomposites10.1007/s10924-015-0710-2 ↗
45. Investigation on aging behavior and failure mechanism of blast-resistant polyurea coating in service environments10.1016/j.mtcomm.2025.112051 ↗
46. Assessment of ultra-high tensile-strength polyurea for underground roof fall support: Insights from work of adhesion10.1016/j.ghm.2025.02.001 ↗
47. Research Progress in Characterization Methods of Anti-Corrosion and Wear-Resistant Polyurethane Coatings10.1051/matecconf/202235801045 ↗