Erosion Wear Model Research Articles

Launching dynamics of terminal guidance projectile considering barrel erosion and mechanical wear

This paper simulates the launching dynamics of the Terminal-guidance projectile considering the barrel thermo-chemical erosion wear and mechanical wear. A thermochemical erosive material degradation model that considers the rise in friction temperature is first introduced. Moreover, the wear state of barrel rifling at different periods is calculated using the erosion wear model. A three-dimensional model of the worn barrel is established, and the coupled barrel– terminal-guidance projectile launch dynamics are simulated for different wear periods. Finally, the projectile's bore overload and attitude are analyzed to explore the effect of barrel wear on launch.

A prediction model of fluid–solid erosion wear in hydraulic spool valve orifice

Fluid–solid erosion wear may damage the port structure and change the linear characteristics of the spool valve. They may also affect null characteristics and the control accuracy of the valve, resulting in production and safety accidents. In the present study, the prediction model of the orifice throttling coefficient and worn profile for engineering applications such as compensation control and life degradation assessment is established. The collision probability between particles and the wall surface is particularly considered based on the E/CRC erosion wear model. The relationship between the spool opening and the impact angle of particles is investigated numerically when developing collision probability model. Meanwhile, the influence of particle concentration, spool opening, and differential pressure on the orifice throttling coefficient and worn profile is analyzed by experiments, and the microcosmic surface morphology of the spool metering edge is analyzed by scanning electron microscopy (SEM). The results show that the impacting of solid particles on the orifice will result in extrusion-thin platelets flaking wear and deformation wear. The maximum relative error between the predicted results and the experimental measurements is 2.25%. Moreover, the predicted results of the model are in good agreement with the measured values under different particle concentrations, spool openings and differential pressure.

Influence of SiO2 and Al2O3 particles on erosion wear of aero-compressor blades

When helicopters take off and land in areas such as plateaus and deserts, both SiO2 and Al2O3 particles in the external environment can cause erosion wear on compressor blades, compromising helicopter safety during operation. The aim of this study is a model of a pre-1.5-stage compressor from a turboshaft engine. The experimental schemes of SiO2 and Al2O3 particle velocimetry and Ti–6Al–4V alloy erosion wear were designed to construct a Tabakoff erosion wear model. The influence of particle density and hardness on the erosion rate was deduced. The trajectories and velocities of the two types of particles were analyzed using the gas-solid two-phase flow method. The erosion pattern of the blade was investigated to determine the influence of the two-particle on the erosion rate of the blade. The results showed that Al2O3 particles produced more energy than SiO2 particles and had a higher ability to erosion materials. The maximum impact angle of both the SiO2 and Al2O3 particles on the Ti–6Al–4V alloy was 30°, and the erosion rate of Al2O3 particles at this angle was 66% higher than that of the SiO2 particles. The erosion patterns of the compressor guide, rotor, and stator blades did not vary with the particle material; however, the erosion rate caused by the Al2O3 particles on the blade was larger than that of the SiO2 particles. The maximum erosion rate on the compressor occurred at 98.5% span of the leading edge of the rotor blade, and the erosion rate generated by the Al2O3 particles at this position was 114% higher than that of the SiO2 particles. This research can provide a theoretical reference for anti-erosion protection designs and vibration characteristic analysis of aero-engine compressor blades.

Influence of inlet distortion on the wear of aero-compressor blades

The turboshaft engine is the main power source of a helicopter. Under airborne conditions, inlet distortion inevitably occurs at the entrance of the compressor because of factors such as airflow and environmental turbulence. The change in the internal flow field alters the erosive wear law of compressor blades caused by sand particles. The influence of total pressure inlet distortion on the erosive wear of compressor blades is studied innovatively in this paper. A new parameterization method of the erosive wear model is proposed through particles velocity test and erosive wear experiment. The rotor blades of pre-1.5 stage compressor are used as the research object. A wear analysis model of the full-port compressor blades is established, which can take into account the inlet distortion. The influence mechanism of typical inlet distortion angles on the erosive wear distribution characteristics and wear degree of the rotor blades is revealed. The results show that inlet distortion significantly alters the wear characteristics of the rotor blades. Specifically, owing to the pressure difference and suction effect of the high-speed rotor blade, the sand particles in the distortion-affected area exhibit aggregation, re-aggregation, and transfer phenomena, which leads to considerable differences in the distribution characteristics and degree of the erosive wear between the rotor blades’ entering the distortion area and their exiting the distortion area. When the inlet distortion angle is expanded from 30° to 90°, compared with the rotor blade in the non-distortion-affected area, the wear degrees of the rotor blade affected by the inlet distortion increase by 32.5–68.7% at the leading edge and by 51.3–57% at the middle position. Moreover, when the inlet distortion angle increases, the maximum wear rate concentration values at the leading edge of the blade with the most serious wear and second most serious wear in the entire circumference of the rotor blade decrease by 4.26% and 27.3%, respectively.

A CFD-DEM-Wear Coupling Method for Stone Chip Resistance of Automotive Coatings with a Rigid Connection Particle Method for Non-Spherical Particles

The stone chip resistance performance of automotive coatings has attracted increasing attention in academic and industrial communities. Even though traditional gravelometer tests can be used to evaluate stone chip resistance of automotive coatings, such experiment-based methods suffer from poor repeatability and high cost. The main purpose of this work is to develop a CFD-DEM-wear coupling method to accurately and efficiently simulate stone chip behavior of automotive coatings in a gravelometer test. To achieve this end, an approach coupling an unresolved computational fluid dynamics (CFD) method and a discrete element method (DEM) are employed to account for interactions between fluids and large particles. In order to accurately describe large particles, a rigid connection particle method is proposed. In doing so, each actual non-spherical particle can be approximately described by rigidly connecting a group of non-overlapping spheres, and particle-fluid interactions are simulated based on each component sphere. An erosion wear model is used to calculate the impact damage of coatings based on particle-coating interactions. Single spherical particle tests are performed to demonstrate the feasibility of the proposed rigid connection particle method under various air pressure conditions. Then, the developed CFD-DEMwear model is applied to reproduce the stone chip behavior of two standard tests, i.e., DIN 55996-1 and SAE-J400- 2002 tests. Numerical results are found to be in good agreement with experimental data, which demonstrates the capacity of our developed method in stone chip resistance evaluation. Finally, parametric studies are conducted to numerically investigate the influences of initial velocity and test panel orientation on impact damage of automotive coatings.

An assessment of erosive wear of hydro-turbine steel using statistical modelling and optimisation

The current study pertains to the influence of chosen process parameters on erosive wear of F6NM stainless steel. Response surface methodology was used to plan experiments. Response surface method with face centred composite design has been adopted to develop a regression model. Development of erosive wear model was based on five factors, which included sediment concentration (A), particle size (B), angle of impact (C), test duration (D) and rotational speed of slurry (E). A mathematical model was developed to predict the deterioration through wear on F6NM stainless steel and the appropriateness of the model was certified using analysis of variance. A robust correlation is attained between the model predicted and experimentally obtained values for weight loss and the percentage of error is 12%. On the basis of mathematical model, single objective optimisation of parameters has been performed with genetic algorithm (GA) technique and this method yields reduction of 34.78% for material wear.

A semi-empirical model for CO2 erosion-corrosion of carbon steel pipelines in wet gas-solid flow

The research of CO2 erosion-corrosion (E-C) of carbon steel pipelines in wet gas-solid flow, as a critical consideration for oil and gas engineering applications, is increasingly receiving more and more interest and attention. A semi-empirical model for the prediction and risk assessment of the conjoint CO2 E-C rate in such conditions is proposed. The variation of fluid properties with system environment is considered during gas-solid flow. The Eulerian-Lagrangian method is employed to solve the N–S equation for computational domain flow field and the force balance equation for migration trajectory of solid particles in the simulation space, and the fluid-solid interaction is considered. An empirical CO2 corrosion model as well as its modified form is provided and verified and an erosion wear model is also adopted, which are both suitable for carbon steel. In addition, the synergistic effect of both models is considered. Based on the above contents, the CFD-DPM technology with test data is adopted to obtain the parameters that are used in both models, and the total CO2 E-C rate, separate erosion rate, separate CO2 corrosion rate can then be obtained at different positions of the pipeline wall. Furthermore, the dominated rate is determined and analyzed, and based on the total CO2 E-C rate, the severity of the conjoint CO2 E-C is shaped. The proposed model can quickly and conveniently compute and determine the dominated rate and severity at different positions, and then further determine the weak positions and statuses where pipeline failures may happen. The model is expected to provide theoretical support for the prevention and daily risk management of carbon steel pipelines failures during the process of oil and gas production and transportation, so as to safely and reliably complete the established production tasks and maximize the economic benefits.

Simulation of Abrasion Characteristics of Polar Ship Seawater Pipelines under the Coupling of Ice Particles and Vibration

Under the erosion of seawater–ice two-phase flow, seawater in pipelines of polar ships can cause the pipeline failures that threaten the safety of navigations. The discrete phase model (DPM) and erosion wear model (EWM) were established by using the computational fluid dynamics (CFD) method for numerical analysis of the 90° elbow with relatively severe erosion. This paper explores the erosion effect of pipelines under different conditions and puts forward optimal measures for pipeline protection. Compared with the existing multiphase flow research, the novelty of this study is that vibration conditions are considered and parameters such as two-phase flow velocity, ice packing factor (IPF), ice particle diameter and ice particle rotation characteristics are combined with vibration conditions. Combined with the comprehensive analysis of erosion effects of static pipelines, a general law of seawater pipeline wear under vibration is obtained. The results show that pipeline wear under vibration is more serious than under static conditions. Under static conditions, the wear of the same section in the pipeline increases with the increases of two-phase flow velocity and IPF. However, under vibration conditions, when the velocity is less than 3 m/s, the wear of the pipeline has no significant change, while when the velocity is over 3 m/s, the wear rate increases significantly. The particle diameter has little effect on the wear of static pipes, but under the vibration condition, the pipe wear rate decreases with the increase of particle diameter, and it starts to stabilize when the diameter exceeds 0.3 mm. If the rotation characteristics of ice particles are taken into account, the wear rate along the pipeline is significantly higher than that without particle rotation.

Computational analysis of solid particle-erosion produced by bottom ash slurry in 90° elbow

Present work is devoted to investigation of the slurry erosion wear in a 90° elbow by using commercial Computational fluid dynamics (CFD) code FLUENT. Discrete phase erosion wear model was used to predict erosion in 90° elbow by solving the governing equations through Euler-Lagrange scheme. Particle tracking was considered by using standard k-ε turbulence scheme for the flow of bottom ash slurry. Erosion wear in elbow was investigated along with velocity distribution and turbulence intensity. The radius-to-diameter (r/D) ratio was taken as 1.5. Results show that erosion rate increases with increase in velocity. Present numerical simulation model holds close agreement with previous studies. Distorted patterns appeared at low velocities. The V-shape pattern appeared on the outer wall of elbow at high velocities. The low velocity region occurs around circumference of elbow wall at outer wall of elbow due to stimulation of the drag forces near the wall region.

Mechanical characterizations and development of erosive wear model for Al2O3-filled short glass fiber-reinforced polymer composites

In the present work, short glass fiber-reinforced polyester-based hybrid composites are fabricated by the incorporation of Al2O3 particulates with three different weight percentages (0 wt.%, 10 wt.% and 20 wt.%) to evaluate their physical, mechanical, and thermo-mechanical behavior. A theoretical model has been developed for erosive wear conditions and results are compared with the experimental outcomes in order to validate the model. The mechanical properties are simulated using an explicit FE code software ANSYS. In this work, erosion test is conducted by using popular evolutionary Taguchi’s (L27) orthogonal array design to optimize the experimental results. It is observed from the analysis that the peak erosion rate occurs at 75° impingement angle for Al2O3-filled composites, whereas for unfilled composites, it occurs at 60° impingement angle. The thermo-mechanical characteristics such as storage modulus (E′), loss modulus (E″), and damping properties (Tan δ) are investigated in the temperature range of 25–200 ℃. It is observed that the slope corresponding to the temperature-dependent decay of the storage modulus for 10 wt.% and 20 wt.%, Al2O3-filled composite is much higher as compared to 0 wt.% Al2O3-filled composite in the temperature range of 25–75 ℃. However, the storage modulus for 10 wt.% and 20 wt.% Al2O3-filled composites remain almost same in the range of 25–60 ℃. Finally, the surface morphology of the eroded composites is examined by using scanning electron microscope and the possible wear mechanisms are discussed.

Influence of incidence angle on wear induced by sliding impacts

Experiments are performed to analyze wear generated by low load sliding impacts on ferrite steel and stainless steel samples. Low load impacts are defined by a normal force such that the apparent contact pressure remains below the yield strength of the material. Nevertheless, concentration of pressure at the top of asperities may generate local plastic deformation. Beyond a running-in period, repetitive oblique impacts cause wear. A high frequency acquisition of dynamical contact forces allows an accurate characterization of impacts (rate, duration, strength) and forces (tangential and normal components and their ratio). These data are correlated with wear volume. The effect of the incidence angle is discussed. The results obtained confirm the combined effects of incidence angle and force ratio on the effective wear of impacts. An erosive wear model is introduced whose results explain all experimental observations. The normalized shear energy seems to be relevant in accounting for the measured evolution of wear with impacts orientation.

Application of RSM to Study the Parametric Effects on Erosion of Flame Sprayed Coatings

In the present work, Ni-base powder (EWAC1004 EN) was modified with the addition of 5%wt., and 10%wt of WC in order to develop three compositions namely 1004+0%wt WC (pure EWAC1004 EN), 1004+5%wt WC and 1004+10%wt WC respectively. These three compositions were deposited by flame spraying process. The effect of WC addition on Vickers hardness and erosive wear behavior of the deposited coatings was studied. The erosive wear behavior of flame sprayed coatings was investigated by Response Surface Methodology (RSM). To investigate and develop the erosive wear model of the flame sprayed coatings five factors; namely composition (C), velocity (V), impact angle (A), temperature (T) and feed rate (F), were used each of which was varied at three levels. Analysis of variance (ANOVA) was carried out to determine the significant factors and interactions. Investigation showed that the composition, velocity, impact angle, temperature and feed rate were the main significant factors while the composition-velocity, velocity-temperature and velocity-feed rate were the main significant interaction. Thus an erosive wear model was developed in terms of main factors and their significant interactions. The validity of the model was evaluated by conducting experiments under different wear conditions. A comparison of modeled and experimental results showed 4 - 9 % error. The WC addition improves the erosive wear resistance of the coatings. This is due to increase in hardness of the coatings.

High Temperature Erosion of Flame Sprayed Coatings

In the present work, Co-base powder was modified with 10%wt CrC addition in order to study the effect of CrC addition. These coatings were deposited by flame spraying process. The effect of CrC addition on Vickers hardness and erosive wear behavior of the deposited coatings was studied. The erosive wear behavior of flame sprayed coatings was investigated by response surface methodology. To investigate and develop the erosive wear model of the flame sprayed coatings four factors, namely velocity (V), impact angle (A), temperature (T), and feed rate (F), each factor at three levels, were used. Analysis of variance was carried out to determine the significant factors and interactions. Investigation showed that the composition, velocity, impact angle, temperature, and feed rate were the main significant factors while velocity-feed rate and impact angle - feed rate were the main significant interactions. Thus, an erosive wear model was developed in terms of main factors and their significant interactions. The validity of the model was evaluated by conducting experiments under different wear conditions. A comparison of modeled and experimental results showed 3-8% error. The CrC addition improves the erosive wear resistance of the coatings. This is due to an increase in hardness of the flame sprayed coatings with the addition of CrC.

Erosive Wear Study of Rare Earth-Modified HVOF-Sprayed Coatings Using Design of Experiment

In the present study, the effect of CeO2 addition in 1006 powder coatings on microstructure, microhardness, and high-temperature erosion resistance were studied. The CeO2 addition refines microstructure, forms new phases, and increases microhardness of HVOF-sprayed coatings. The erosive wear behavior of coatings were investigated by Response Surface Methodology (RSM). To investigate and develop an erosive wear model of unmodified 1006 (without CeO2) and modified 1006 (CeO2 addition) coatings’ four factors: velocity, impact angle, temperature, and feed rate, each factor at three levels were used. ANOVA was carried out to determine the significant factors and interactions. Thus, an erosive wear model was developed in terms of main factors and their significant interactions. A comparison of modeled and experimental results showed 4-7% error. The modified 1006 coating showed high erosive wear resistance as compared with unmodified 1006 coating. This is due to increase in hardness and refined microstructure of the modified 1006 coating.

Study and model development of erosive wear by RSM

In this study, composite powder (MEC1031C) was modified with the addition of 0.4 wt.% La2O3. The effects of La2O3 addition on microstructure, formation of new phases, and microhardness were studied. The La2O3 addition refines the microstructure, forms new phases, and increases microhardness of high-velocity oxy-fuel (HVOF) coatings. The erosive wear behaviours of HVOF-sprayed coatings were investigated by response surface methodology. To investigate and develop the erosive wear model of unmodified (without La2O3) and modified (La2O3 addition) HVOF-sprayed coatings, four factors, velocity ( V), impact angle ( A), temperature ( T), and feed rate (F), with each factor at three levels, were used. Analysis of variance was carried out to determine the significant factors and interactions. Investigation showed that the velocity, temperature, and feed rate were the main significant factors, while velocity–feed rate was the main significant interaction. Thus, an erosive wear model was developed in terms of main factors and their significant interactions. The validity of the model was evaluated by conducting experiments under different wear conditions. A comparison of modelled and experimental results showed 5–11 per cent error. The modified (La2O3 addition) HVOF-sprayed coating showed high erosive wear resistance compared to unmodified coating. This is due to the increase in hardness of the modified coating.

331 長繊維強化複合材料のエロージョン損傷機構に及ぼす投射条件の影響(摩擦・摩耗材料)

The present study describes effect of impact media size on erosive wear mechanisms of woven continuous SiC fiber reinforced ceramic matrix composites (CMC). The CMC was processed by chemical vapor infiltration (CVI) and consisted from fibers having 10 μm of mean diameter. Various size of green silicon carbide (SiC) abrasives used for the impact media were collided to the target CMC surface with pressurized air. Results showed that erosive wear rate and crack pass were different depend on the media size. A relationship between the crack pass and the erosive wear rate analyzed with the present erosive wear model based on the lateral crack extension.