Abstract
Solid particle erosion affects many areas, such as dust or volcanic ash in areo-engines. The development of protective materials and surface engineering is costly and time consuming. A lot of effort has been placed into the advancement of models to speed up this process. Finite element or discrete element-based models are quite successful in predicting single or multiple impacts. However, they reach their limit if an entire erosion experiment is to be simulated. Therefore, in the present work, an approach is presented which combines various aspects of the former models with probability considerations. It is used to simulate the impact of more than one billion Alumina particles onto a steel substrate. This approach permits the simulation of an entire erosion experiment on an average PC (i5-2520M CPU@2.5 GHz processor, 4 GB main memory) within about six hours. The respective predictions of wear scar and impact-mass/mass-loss curve are compared to the real experiment.
Highlights
Across different industries and respective locations in plants, the type and cause of solid particle erosion varies
The durability of materials can be improved in all cases through better coatings and surface engineering
Two major types of these models are based on finite element methods (FEM) and discrete element methods (DEM)
Summary
Across different industries and respective locations in plants, the type and cause of solid particle erosion varies. Griffin et al describe a three-dimensional finite element model which they used to simulate the impact of a solid, spherical shaped particle on an Alumina scale/MA956 substrate [1]. In the case of finite element-based methods, the simulation of a single impact using a mesh with about 100,000 nodes would take about 15 min (private communications) on an average personal computer. This calculation time is too long to simulate an entire particle erosion experiment with billions of such impacts. Zhao et al proposed a particle erosion model based on the shear impact energy of these particles using discrete element method simulations.
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