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Combustion Spraying Systems

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Thermal Spray Fundamentals

Abstract

The growth of combustion processes along the years was driven both by scientific and technical developments providing disruptive innovations and by the market requirements )(e.g., the development of HVOF spraying by Browning in 1983 was pushed forward by the need to produce WC-Co cermet coatings with superior properties). The different processes are presented with for each one the principle, the type of materials used (powder, liquid wire cord or rod), then materials sprayed, sprayed particle temperatures, velocities and oxidation, types of coatings obtained and finally the process modeling. Successively are presented flame spraying, High Velocity Oxy-Fuel (HVOF), and High Velocity Air-Fuel spraying and modified HVOF processes and finally Detonation gun (D-gun).

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Abbreviations

D-gun:

Detonation gun

HVAF:

High Velocity Air-Fuel

HVOF:

High Velocity Oxy-Fuel

SHS:

Self-propagating High Temperature Synthesis

slm:

standard liters per minute

YSZ:

Yttria stabilized zirconia

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Authors and Affiliations

  1. Sciences des Procédés Céramiques et de Traitements de Surface (SPCTS), Université de Limoges, Limoges, France

    Pierre L. Fauchais

  2. Department of Mechanical Engineering, University of Minnesota, Minneapolis, MN, USA

    Joachim V. R. Heberlein

  3. Department of Chemical Engineering, University of Sherbrooke, Sherbrooke, QC, Canada

    Maher I. Boulos

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  1. Pierre L. Fauchais
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Nomenclature

Nomenclature

a :

Sound velocity, \( a=\sqrt{\frac{\gamma .p}{\rho_{\mathrm{g}}}} \) (m/s)

A :

Oxidizer volume or mass (m3 or kg)

A i :

Is the cross-sectional area perpendicular to the flow direction (m2)

A t :

Throat area (m2)

D :

Detonation wave velocity (m/s)

F :

Fuel volume or mass (m3 or kg)

F/A :

Ratio of fuel to oxidizer number of moles

h i :

Enthalpy (J/kg)

\( {m}_{{\mathrm{O}}_2}^{{}^{\circ}} \) :

Oxygen gas feeding flow rate (kg/s)

M :

Mach number, ratio of gas velocity to the local sound velocity

p :

Pressure (Pa)

p t :

Gas pressure at the throat (Pa)

P F :

Power dissipated in the flame (kW)

q :

Chemical energy release at constant pressure (J/kg)

Q o :

Specific energy of detonation (J)

R :

Specific perfect gas constant (J/K kg)

R u :

Universal perfect gas constant (8.32 J/K mol)

R′:

Equivalence ratio or richness: R′ = (F/A)/(F/A)stoichiometry

t c :

Detonation cycle duration time (s)

T g :

Gas temperature (K)

T m :

Melting temperature (K)

T p :

Particle temperature (K)

T t :

Temperature at the throat (K)

u b :

Burned gas velocity with respect to the detonation wave front (m/s)

u u :

Unburned gas feeding velocity (m/s)

u u − u b :

Velocity of the burned gases with respect to the D-gun wall (m/s)

Δt i :

Characteristic time intervals of a detonation (s)

ϕ :

Dummy variable

ϕ′:

Time- (or Reynolds) averaged dumb variable

ϕ″:

Density-averaged dumb variable

γ :

Specific heats ratio

ρ g :

Gas mass density (kg/m3)

ρ p :

Particle mass density (kg/m3)

ρ t :

Gas mass density at the throat (kg/m3)

b:

Burned gases (in the immediate vicinity behind the front)

g:

Gas

p:

Particle

t:

Throat

u:

Unburned gas (before the detonation wave front)

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Fauchais, P.L., Heberlein, J.V.R., Boulos, M.I. (2014). Combustion Spraying Systems. In: Thermal Spray Fundamentals. Springer, Boston, MA. https://doi.org/10.1007/978-0-387-68991-3_5

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