Numerical study of SiO2 particle erosion of an aluminum alloy

Computational methods used to simulate solid particle erosion have advanced so far being able to estimate partial effect of various processing factors on microlevel, such as particle-surface contact, its particle material, and shape, etc. The published activities taken to study different effects in this aspect for popular aluminium or titanium alloys and steels still have a gap in knowledge addressing some process parameters. The influence of particle rotation and its direction on stress-strain state and wear depth is still understudied. The impact of friction consideration in relatively high-speed contacts should also be studied, as well as the surface layer heating effect which may influence the material strength properties when the temperatures get high. Understanding these effects would increase the predictive ability of the erosion model and its accuracy — which is presented in our 2D simulation study for SiO₂ solid particles and a widespread Al6061-T6 alloy. The elastic-plastic and failure properties of the surface material were presented by the Johnson-Cook model. To estimate the influence of multiple impacts on the stress-strain state, three sequential rigid impacts of 250 µm particles at 45° and 155 m/s were modeled. Main attention was driven to the evolution of equivalent von-Mises stresses in the sample after each impact and its dependence on the friction and rotation of particles. It was shown that the effect of friction can be noticed after the first impact, remaining high throughout the simulation. Whereas the influence of rotation direction at 1000 rpm was noticeable after the second impact and tended to increase after the third impact. It is assumed that for other 6000 series aluminium alloys being eroded by spherical SiO₂ particles with differing diameters the erosive behavior would keep. However, future studies should be addressed to the analyzing of non-spherical particles rotation, consideration of particle deformation, and to studies of these parameters including more impacts and different contact properties in complex.

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