High speed water droplet impact erosive behavior on dry and wet pulsed waterjet treated surfaces

During water droplet impact onto a dry or wet rough solid surface, several phenomena affect the surface erosion process, such as splashing, crown formation, and small droplet emission to name a few. These phenomena have been extensively studied for various simple target surface geometries. However, droplet impact studies on complex irregular and asymmetric target surface topographies resulting from a waterjet treatment have never been conducted. Furthermore, very limited reports are found on the role of target surface topography and water droplet deformation development on the resulting target stress state. In the present study, high speed droplet impingements on surfaces exhibiting coarse topographical features associated with ultrasonic pulsed waterjet treatment are modeled to understand the underlying mechanisms causing erosion. Impacts on surfaces with various roughness values and water film thicknesses are modeled using a three-dimensional coupled Eulerian-Lagrangian approach. A detailed comparative analysis of the model with experimental ultrasonic pulsed waterjet erosion features and material loss is provided. It was found that the synclastic curvature of the modeled coarse surface features increases the shock wave's strength as many compression wavelets are simultaneously emitted at each water droplet contact location with the surface, resulting in concentrated high-pressure zones. The ultrasonic pulsed waterjet treated surface features and water film thickness also greatly influence the onset of water droplet splashing, subsequent finger, secondary droplet characteristics, and crown stability. According to the numerical results, strong splashing patterns and droplet breakup are generated and create high stress zones capable of accelerating surface erosion, explaining the enhanced performance of ultrasonic pulsed waterjet process.