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Modeling of Micro- and Nanoparticle Characteristics in DC Suspension Plasma Spray

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Abstract

Suspension plasma spray is a promising technology for surface coatings. In this work, a comprehensive numerical model was developed to investigate the multiphase flow of suspension droplets and nanoparticles in direct-current (DC) plasma spraying. A three-dimensional computational model was developed to describe the plasma jet flow fields coupled with the axial injection of suspension droplets in which the zirconia micro- and nanoparticles were dispersed. The suspension droplets were tracked using Lagrangian coordinates, considering particle heating, melting, and evaporation. After evaporation of the solvent surrounding the particle, the nanoparticles were discharged into the plasma flow. In addition to the viscous force exerted by the flow on the micrometer-sized particles, the Brownian force and the Saffman lift force were taken into account. The effects of the noncontinuum on particle momentum transfer and evaporation on heat transfer were also considered. The numerical predictions of gas flow temperature were compared with experimental data and numerical data obtained with a different computational fluid dynamics code. The agreement was reasonable. The trajectories, velocity, and temperature of nanoparticles were calculated, and compared with those of microparticles. The results showed that the Brownian force plays a major role in acceleration and heating of nanoparticles. Compared with the conventional plasma spray process with micrometer-sized feedstock, the nanoparticles in suspension plasma spraying were found to have a wider spatial distribution and higher temperature. The effects of operating parameters, such as the power input to the plasma gas and plasma gas composition, on the gas velocity and temperature were investigated. The parameters that have a significant effect on the heat and momentum transfer to the particles injected in the plasma jet were identified.

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Abbreviations

C p :

Specific heat (J/kg/K)

C D :

Drag coefficient

D :

Diffusion coefficients (m2 s−1)

h :

Heat transfer coefficient (W/m2/K)

k :

Thermal conductivity (W/m/K)

L m :

Latent heat of fusion (J/kg)

L v :

Latent heat of evaporation (J/kg)

Nu:

Nusselt number, Nu = 2 h/k

Pr:

Prandtl number, Pr = μC p/k

Q conv :

Convective heat rate (W)

Q rad :

Radiative heat rate (W)

Q vap :

Vaporization heat rate (W)

Sc:

Schmidt number, \({\text{Sc}} = \mu /\rho D\)

r :

Radial coordinate (m)

R :

Particle radius (m)

t :

Time (s)

T p :

Particle temperature (K)

T m,d :

Droplet evaporation temperature (K)

V :

Velocity (m/s)

Y :

Mass fraction of vapor in the gas phase

α :

Weight fraction

μ :

Viscosity (kg/s/m)

d:

Suspension droplet embedded with nanoparticles

f:

Film temperature around the particle

g:

Plasma gas

p:

Solid nanoparticles or agglomerates

sl:

Solvent

∞:

Ambient condition of spray

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Acknowledgments

The work was supported by the National Natural Science Foundation of China (nos. 11472245, 11072216, and 10602052) and the Fundamental Research Funds for the Central Universities (nos. 2012FZA4027).

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Authors and Affiliations

  1. Department of Mechanics, Zhejiang University, Hangzhou, 310027, China

    Xue-ming Shao, Kai Zhang & Hong-bing Xiong

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  1. Xue-ming Shao
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Correspondence to Hong-bing Xiong.

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Shao, Xm., Zhang, K. & Xiong, Hb. Modeling of Micro- and Nanoparticle Characteristics in DC Suspension Plasma Spray. J Therm Spray Tech 24, 309–317 (2015). https://doi.org/10.1007/s11666-014-0182-2

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  • DOI: https://doi.org/10.1007/s11666-014-0182-2

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