Numerical Simulation of Droplet Impact Experiments on Structural Surfaces
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An important topic in the design of aircraft component surfaces and coatings is their resistance against rain erosion. Rain erosion has been the subject of intensive investigation for some time [e.g. 1–3] and particularly affects components such as the leading edges of wings, horizontal and vertical stabilisers, nose domes, and helicopter rotor blade edges, which are vulnerable to damage from droplet impacts. To predict the rain erosion behaviour of different materials and coatings, ground erosion tests such as the rotating arm test [4] or the Pulsating Jet Erosion Test (PJET) [5] are conducted. For the development and design of coatings or new materials, a simulation methodology that is capable of predicting the phenomena and mechanisms observed in tests based on an adequate representation of the underlying physics and basic material properties by direct simulation of droplet impacts would be highly desirable. Some efforts have been undertaken in this direction [e.g. 1,6,7], but a simulation methodology which combines multiple impacts with the accurate representation of each droplet impact is not yet available. We investigated PJET tests on a model aluminum material (Al 1050 H14) with a hardness comparable to common CLAD surfaces, characterized the material in static and dynamic tensile tests and performed numerical simulations in 2D and 3D. We measure the crater depth from the PJET-test for different impact numbers with high precision to obtain a good basis for the validation of the simulations. Additionally, the PJET method has been combined with a methodology to determine the weight loss of the impact craters. Our 2D simulation model with commercial software (ANSYS Autodyn) can predict the crater depth for up to 500 droplet impacts. The 3D multiple impact simulations with specialized numerical codes developed at Fraunhofer EMI show an interdependence of the surface deformation due to droplet impact and the impact pressure. References in attached pdf-document
