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Effect of Operating Parameters on a Dual-Stage High Velocity Oxygen Fuel Thermal Spray System

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Abstract

High velocity oxygen fuel (HVOF) thermal spray systems are being used to apply coatings to prevent surface degradation. The coatings of temperature sensitive materials such as titanium and copper, which have very low melting points, cannot be applied using a single-stage HVOF system. Therefore, a dual-stage HVOF system has been introduced and modeled computationally. The dual-spray system provides an easy control of particle oxidation by introducing a mixing chamber. In addition to the materials being sprayed, the thermal spray coating quality depends to a large extent on flow behavior of reacting gases and the particle dynamics. The present study investigates the influence of various operating parameters on the performance of a dual-stage thermal spray gun. The objective is to develop a predictive understanding of various parameters. The gas flow field and the free jet are modeled by considering the conservation of mass, momentum, and energy with the turbulence and the equilibrium combustion sub models. The particle phase is decoupled from the gas phase due to very low particle volume fractions. The results demonstrate the advantage of a dual-stage system over a single-stage system especially for the deposition of temperature sensitive materials.

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Abbreviations

A :

Empirical coefficient in eddy dissipation model

A p :

Particle cross-sectional area

B :

Empirical coefficient in eddy dissipation model

c :

Turbulent model constant

C D :

Drag coefficient

C p :

Specific heat at constant pressure

d p :

Particle diameter

\( \overset{\lower0.5em\hbox{$\smash{\scriptscriptstyle\rightharpoonup}$}}{F} \) :

External force

h c :

Convective heat transfer coefficient

H :

Overall enthalpy

k :

Turbulent kinetic energy

m p :

Mass of particle

Nu :

Nusselt number

p :

Gas pressure

P k :

Production rate of turbulent kinetic energy

P r :

Prandtl number

R :

Gas constant

R F :

Volumetric fuel consumption rate

Re :

Reynolds number

S :

Source term

t :

Time

T :

Temperature

u i :

Velocity in the i-direction

\( \overset{\lower0.5em\hbox{$\smash{\scriptscriptstyle\rightharpoonup}$}}{U} \) :

Instantaneous gas velocity vector

x i :

Spatial coordinate in the i-direction

Y :

Fluctuating dilation in compressible turbulence to the overall dissipation rate

α:

Inverse effective Prandtl number

ε:

Rate of turbulent kinetic energy dissipation

λ:

Thermal conductivity

µ:

Molecular viscosity

µeff :

Effective viscosity

Γ k :

Diffusion coefficient of k

Γε :

Diffusion coefficient of ε

ρ:

Density

σ:

Turbulent model constant

F:

Fuel

g:

Gas

O:

Oxidant

p:

Particle

P:

Combustion product

t:

Turbulent

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Authors and Affiliations

  1. Department of Mechanical and Materials Engineering, Institute Center for Energy (iEnergy), Masdar Institute of Science and Technology, P.O. Box 54224, Masdar City, Abu Dhabi, United Arab Emirates

    Mohammed N. Khan & Tariq Shamim

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  1. Mohammed N. Khan
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  2. Tariq Shamim
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Correspondence to Tariq Shamim.

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Khan, M.N., Shamim, T. Effect of Operating Parameters on a Dual-Stage High Velocity Oxygen Fuel Thermal Spray System. J Therm Spray Tech 23, 910–918 (2014). https://doi.org/10.1007/s11666-014-0114-1

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  • DOI: https://doi.org/10.1007/s11666-014-0114-1

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