Solid particle erosion is one of the main failure mechanisms of a compressor blade. Thus, characterization of this damage mode is very important in life assessment of the compressor. Since experimental study of solid particle erosion needs special methods and equipment, it is necessary to develop erosion computer models. This study presents a coupled temperature–displacement finite element model to investigate damage of a compressor blade due to multiple solid particles erosion. To decrease the computational cost, a representative volume element technique is introduced to simulate simultaneous impact of multiple particles. Blade has been made of Ti-6Al-4V, a ductile titanium-based alloy, which is impacted by alumina particles. Erosion finite element modeling is assumed as a micro-scale impact problem and Johnson–Cook constitutive equations are used to describe Ti-6Al-4V erosive behavior. In regard to a wide variation range in thermal conditions all over the compressor, it is divided into three parts (first stages, middle stages, and last stages) in which each part has an average temperature. Effective parameters on erosive behavior of the blade alloy, such as impact angle, particles velocity, and particles size are studied in these three temperatures. Results show that middle stages are the most critical sites of the compressor in terms of erosion damage. An exponential relation is observed between erosion rate and particles velocity. The dependency of erosion rate on size of particles at high temperatures is indispensable.

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Solid particle erosion (SPE) as a common damage mechanism in industrial applications can reduce the effective operation of components or contribute to failure. However, it has beneficial usages in manufacturing processes, especially in abrasive sandblasting and waterjet cutting. The aim of this paper is an investigation of erosive behavior of Ti-6Al-4V alloy through numerical and experimental approaches. A three-dimensional finite element (FE) model is developed using the representative volume element (RVE) to simulate multiple particles impact on Ti-6Al-4V target. Failure and plastic behavior of the target surface due to particles impact is described by Johnson-Cook constitutive equations. Furthermore, erosive behavior of the alloy is experimentally researched by multiple SPE tests. Verification of the implemented approach is studied by comparing the results of the FE model and the SPE experiments. Effects of particles impact angle considering Johnson-Cook coefficient values and particles velocity on erosive behavior of Ti-6Al-4V are also studied. Both numerical and experimental results show a maximum erosion rate of the alloy at an impact angle of 45 deg for spherical sand particles with a diameter of 100 µm. According to the scanning electron microscopy (SEM) images, the erosion process involves both ductile and brittle mechanisms at this angle.

In the present study, solid particle erosion of Ti-6Al-4V alloy under the impact of spherical alumina particles with a diameter of 85 microns was analyzed using experimental studies and smoothed particle hydrodynamics (SPH) modeling. The erosive behavior of this alloy was simulated as impacts on micro-scale and based on Johnson-Cook constitutive equations. This research focuses on the effect of particle velocity and impact angle on erosion rate as the most critical factors. Additionally, the results of this model are validated by empirical results under-considered conditions. At the end of the article, based on the alloy properties, the velocity of particles, and impact angle, a prediction equation was presented on erosion rate in the studied range of velocity and impact angle. This study indicates a power-law equation between the velocity of particles and the erosion rate, where the power is independent of impact angle. Furthermore, in all the velocity and angle ranges, the maximum erosion rate was associated with the angle of 45o. Therefore, the critical angle in erosion is also independent of the velocity of particles.