Erosion modeling of epoxy composites reinforced with angular particulate alumina: A surface evolution approach

This study investigates the solid particle erosion of epoxy composites filled with angular alumina particles. An analytical surface evolution technique, originally developed for composites reinforced with uniformly sized beads, was reformulated for non-uniform angular reinforcements (~650 µm) by incorporating their size distribution and the erosion behavior of the constituents. The model was experimentally verified using 22 µm angular SiC abrasives and predicted composite erosion rates within ~12% of those measured at both perpendicular and oblique incidences. It also captured matrix shadowing and abrasive particle ricocheting mechanisms. The approach offered a practical methodology to predict erosion rates of composites with relatively large angular reinforcements that erode gradually when impacted by much smaller abrasives, where more complex numerical techniques are computationally impractical. • Model provides an alternative to FE and SPH in composite gradual erosion modeling • Surface evolution predicts erosion rate for angular particulate composite accurately • Model predicts a very low erosion rate for the angular alumina reinforcements used • Oblique impact boosts composite erosion resistance by ~41% via shadowing effect • Perpendicular impact causes a small reduction (~6%) in the composite erosion rate