What is Erosion Testing?
Erosion testing is a controlled material evaluation method used to measure surface degradation caused by repeated impact of solid particles carried in a gas or liquid stream. The test replicates abrasive service environments where components are exposed to high-velocity particle impingement that gradually removes material and alters surface integrity.
This method is used to identify erosion mechanisms such as cutting, plowing, brittle fracture, and surface fatigue that reduce wall thickness, coating effectiveness, and structural reliability. By quantifying weight loss, volume loss, erosion rate, and surface damage characteristics, engineers can compare material performance, validate protective coatings, and assess long-term durability under simulated service conditions.
Erosion testing is applicable to metals, alloys, ceramics, polymers, composites, and coated components across aerospace, energy, oil and gas, automotive, defense, and industrial manufacturing applications where airflow, combustion gases, sand, ash, or particulate matter create abrasive operating conditions.
How Erosion Testing Works
Test Planning and Sample Preparation
Test parameters are defined based on application requirements, including particle type, particle size distribution, velocity, impingement angle, exposure duration, and mass flow rate. Samples are cleaned, weighed, documented, and fixtured to ensure consistent exposure orientation and repeatable results.
Controlled Particle Exposure
Samples are placed in a calibrated erosion test rig where abrasive particles are accelerated toward the surface at controlled velocity and angle. Flow rate, exposure time, and environmental conditions are monitored throughout testing. Data is recorded to track total particle exposure and operating parameters.
Evaluation and Reporting
After testing, samples are cleaned and reweighed to determine mass loss. Surface damage is evaluated through visual inspection, dimensional measurement, and microscopy as required. Erosion rates are calculated and analyzed against defined acceptance criteria. A detailed report documents test conditions, material loss, and observed degradation.
Key Benefits of Erosion Testing
Erosion testing supports informed material and coating selection by identifying resistance to abrasive particle impact early in development. It reduces operational risk by validating durability before deployment in erosive service environments.
- Identifies erosion susceptibility and material loss rates before field exposure
- Validates coating systems for particle impact resistance
- Supports qualification and compliance requirements for abrasive environments
- Improves reliability of components exposed to sand, ash, or particulate flow
- Reduces maintenance intervals and unplanned downtime through durability assessment
Frequently Asked Questions
What types of particles are used in erosion testing?
Common test media include silica sand, alumina particles, ash simulants, or application-specific particulate materials. Particle size distribution and hardness are selected to replicate real operating environments. Selection is based on service conditions and industry standards when applicable.
How is erosion rate calculated?
Erosion rate is typically calculated by measuring specimen mass loss after exposure and normalizing it to particle mass, exposure time, or surface area. Results may be reported as mass loss per unit time or volume loss per unit mass of impacting particles for material comparison.
What impingement angles are evaluated during testing?
Impingement angle is defined based on expected service exposure and may range from shallow angles that promote cutting wear to perpendicular impact that promotes deformation or brittle fracture. Multiple angles may be evaluated to characterize material behavior.
How are erosion testing results documented?
Results are documented in a formal report that includes particle type, velocity, impingement angle, exposure duration, mass loss measurements, calculated erosion rates, and post-test surface observations. Photographs and microscopy images may be included to document wear mechanisms and surface damage characteristics.
Client Testimonials
Nick Kattamis – Creare
I wanted to extend a very big THANK YOU for prioritizing this work and helping it get done so quickly. Often times these last minute requests are out of our hands, so again, thank you for your responsiveness.
Ryan Canfield
I’d like to thank Innovative Test Solutions for their excellent work, and for accommodating our second round of testing. This was an important milestone for us, and we will definitely remember you for future needs.
Kris – GE Power
Excellent work on this testing and report write up! As usual, the ITS team exceeded expectations.
Earl Size
Thank you very much! And thank you for going the extra mile in helping us where you thought to. I truly appreciate it.
Richard F. – Chromalloy
The efforts on the erosion test program were excellent. Kyle and Jason did an outstanding job. We were working with many unknowns. Both men made major contributions that resulted in a successful outcome. I now feel confident that we have the recipe to conduct side-by-side erosion tests of coatings on actual parts. I anticipate that we will use the erosion test methodology again in the latter part of 2019. Thanks for your assistance.
Adam – Curtiss Wright
Thank you all for all of your efforts with this program. I have worked with many test labs over the years and must say that you were one of the best I have come across. The responsiveness and willingness to work with us to find a good solution was unprecedented with previous experiences with other facilities. Thank you all for being great to work with.
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