Predicting Erosion In Advanced High-Speed Propellers

Abstract Dust-laden environments cause substantial propeller erosion, leading to decreased performance and lifespan. The first part of this study examines the flow characteristics and performance of the SR-5 high-speed propeller, which features ten thin, swept blades rotating at 5,709 rpm. The second part investigates particle dynamics within the propeller, impact conditions, and the progression of erosion during cruise and takeoff. The analysis demonstrates the effects of operating conditions, propeller setting, particle type (dust or sand), and concentration on erosion. Particle trajectories and erosion were calculated using a Lagrangian-based finite element procedure, enabling precise tracking and determination of impact conditions. Particles were generated and released randomly to replicate the particle size distribution and concentrations typical of desert environments. Erosion rates were quantified using a semi-empirical erosion correlation specifically developed for composite materials. The dynamic behavior of particles and their impacts, as well as the resulting erosion, are influenced by the particle type and the propeller's operating conditions. The leading edge (LE) and pressure side (PS) of the blade were exposed to a dense, high-velocity particle flux, impacting and eroding almost the entire PS, while the front of the suction side (SS) was impacted by particles of high velocities and angles of attack. The depth of wear was assessed for different particle types, concentrations, and operating conditions. The present results, particularly the correlations established between erosion wear and propeller dimensions, can help manufacturers and operators of high-speed propellers develop solutions to limit erosion progression.