Several factors influence the occurrence and severity of erosive damage in mechanical systems. These variables include:

• Particle or Droplet Characteristics: The size, shape, and hardness of the impacting particles or droplets significantly affect the wear mechanism. Larger, harder, and sharper particles typically cause more severe wear.
• Impact Velocity and Angle: The velocity of the impacting particles or droplets and the angle at which they strike the surface are crucial factors in determining the wear rate. Higher velocities and impact angles closer to perpendicular (90°) generally lead to increased erosion rates.
• Environment and Operating Conditions: The environment, including temperature and humidity, can also impact the erosive wear process. Additionally, the operating conditions, such as flow rates and pressures, can influence the severity of erosive damage.

To minimize the occurrence and severity of erosive damage in mechanical systems, various mitigation steps should be considered:

• Geometric Design: Optimize the design of components to minimize the exposure to erosive wear, for example, by using streamlined shapes to reduce the impact of particles or droplets on the surface.
• System Design: Reducing fluid velocity, minimizing turbulence, and providing adequate bend radii in piping systems are all effective methods to minimizing erosive degradation.
• Flow Control: Regulate the flow of the abrasive medium by adjusting flow rates, velocities, and particle concentrations to minimize erosive damage.
• Surface Treatment: Harder materials or hard surface coatings like chrome and HVOF can be effective at mitigating the likelihood of erosive damage. Surfaces subject to erosion are often internal and any coating method needs to be applied via non-line of sight methods, limiting the use of PVD or HVOF coating methods.
• Maintenance and Monitoring: Regularly inspect and maintain mechanical systems to identify and address signs of erosive wear early, preventing premature failures and extending component life.