Research on Highly Dynamic Particle Erosion and Barrel Life Based on a Coupled Thermal–Fluid–Mechanical Method

Abstract

Abstract. Barrel erosion, critically limiting service life and ballistic performance, involves complex thermomechanical interactions. This study investigates the hitherto underexplored erosion mechanism induced by highly dynamic gas–solid flow and unburned propellant particles. We propose an improved two-phase flow erosion model by integrating interior ballistics theory with the barrel's transient radial heat transfer equation and established erosion models. This coupled thermal–fluid–mechanical method enables quantitative prediction of wear from particle-wall interactions under extreme thermal and mechanical loads. Simulations reveal that erosion severity is predominantly governed by particle impact velocity and angle, propellant charge mass, and combustion rate. Increased charge mass exacerbates erosion by elevating collision frequency and kinetic energy, whereas faster combustion rates mitigate wear by reducing particle residence time. Crucially, thermal softening induced by transient heat transfer markedly reduces material hardness, which amplifies the erosion ratio significantly. Furthermore, erosion thickness is minimized at lower impact angles, suggesting practical design strategies for wear reduction.