Computational approach for evaluating the erosion rate of ductile alloys impacted by alumina particles in solid rocket plumes

A comprehensive computational framework for predicting steady-state erosion rates of ductile alloys subjected to high-velocity alumina particles from solid rocket motor plumes is presented. Advanced finite element method (FEM) simulations were employed to investigate the effects of particle velocity, incidence angle, shape, and state on the erosion of 4340 steel and Ti-6Al-4V targets. The Johnson-Cook constitutive model and damage criteria were implemented to capture the complex thermo-mechanical response of the materials. Periodic boundary conditions were applied to efficiently model the erosion process, ensuring a sufficient number of particle impacts to reach a constant erosion rate. The results reveal distinct trends in erosion behavior, with peak erosion rates occurring at incidence angles around 50° for solid particles and normal impact causing the highest erosion for liquid particles. Particle shape significantly influenced erosion rates, with cubical particles causing up to 27% more erosion compared to spherical particles. The superior erosion resistance of 4340 steel over Ti-6Al-4V was demonstrated. The predicted erosion rates agree well with available experimental data, validating the computational approach. This study provides valuable insights into erosion phenomena in solid rocket motor plumes and establishes a framework for predicting erosion rates in ductile alloys, with potential applications in aerospace engineering, turbomachinery, and oil and gas industries.