OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 25 No. 4 2023 Numerical study of titanium alloy high-velocity solid particle erosion Evgeny Strokach a, *, Gleb Kozhevnikov b, Aleksey Pozhidaev c, Sergey Dobrovolsky d Moscow Aviation Institute (National Research University), 4 Volokolamskoe shosse, Moscow, 125993, Russian Federation a https://orcid.org/0000-0001-5376-1231, evgenij.strokatsch@mai.ru; b https://orcid.org/0009-0001-4622-7476, kozhevnikov.mai@yandex.ru; c https://orcid.org/0000-0002-7667-5392, pozhidaev.mai@xmail.ru; d https://orcid.org/0000-0002-1884-1882, dobrovolskiy_s@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2023 vol. 25 no. 4 pp. 268–283 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2023-25.4-268-283 ART I CLE I NFO Article history: Received: 15 September 2023 Revised: 29 September 2023 Accepted: 28 October 2023 Available online: 15 December 2023 Keywords: Erosion wear Numerical simulation Solid particles Ansys FLUENT Shape factor Ti6Al4V CFD Solid particle erosion GEKO Turbulence model RANS erosion study Funding The research was funded by the ministry of Science and Higher Education of the Russian Federation, grant number FSFF-2023-0006. Acknowledgements Research was partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Predicting solid particle erosion (SPE) in gaseous flow and managing its intensity is still a relevant problem in mechanical engineering. It requires the development of a general modeling methodology, which also depends upon many special cases studying various physical processes. Such studies should also include verification analysis, process parameters and model sensitivity studies. Mainly computational fluid dynamics and finite element analysis (and mesh-free methods such as smooth particle hydrodynamics or similar) are used to simulate the erosion process. Papers focused on CFD simulation of solid particle erosion of metal alloys are widely presented, but most of it is associated with relatively low or medium particle velocities (< 100–150 m/s) and is close to uniform diameter distribution. This paper presents a CFD study of Ti6Al4V titanium alloy SPE at relatively high particle velocities and sufficiently non-uniform unimodal particle diameter distribution. The paper also studies the turbulence model influence and particle shape effect which appears as a “shape factor” coefficient in the particle drag model. Methods. The heterogenous flow simulation was based on the Reynolds-averaged Navier-Stokes formulation, where the particles, according to EulerLagrange formulation, were simulated as mathematical points with corresponding properties. The influence of turbulence models, such as k-epsilon standard, RNG k-epsilon, and a relatively new Generalized equation k-omega (GEKO) model and its coefficients were also studied. Oka and DNV erosion models were also compared based on the general sample mass loss and more specific erosion intensity profile criterions. The simulation results were compared to the lab-scale experimental results. Results and discussion. It is shown that neither erosion intensity profile or sample mass loss do not depend upon the turbulence model choice or GEKO parameters variation. As expected, erosion is dependent on the erosion model and its coefficients. A notable influence of the shape factor is shown. As the drag coefficient increased due to the particle shape, the erosion intensity decreased and the erosive profile on the surface also changed due to the changing velocity and diameter distribution of the heterogenous flow. It is expected that such results would be useful not only for erosion prediction in all areas of mechanical engineering, but also for wear management in mechanical assemblies and shot peening / shot peen forming management and simulation. For citation: Strokach E.A., Kozhevnikov G.D., Pozhidaev A.A., Dobrovolsky S.V. Numerical study of titanium alloy high-velocity solid particle erosion. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2023, vol. 25, no. 4, pp. 268–283. DOI: 10.17212/1994-6309-2023-25.4-268-283. (In Russian). ______ * Corresponding author Strokach Evgeny A., Ph.D. (Engineering), leading engineer Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, 125993, Moscow, Russian Federation Tel.: +7 (916) 338-63-66, e-mail: evgenij.strokatsch@mai.ru Introduction Solid particle erosion, particularly in the gas flow, is a prevalent issue across aerospace, energy, automotive, and various other sectors. Experimentation on different particle materials, surface and coating materials, flow conditions, particle characteristics, and more has generated a wealth of research on this
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