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In-Flight Oxidation of Fe-Based Amorphous Particle During HVAF Spraying: Numerical Simulation and Experiment

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Abstract

Understanding formation and evolution of oxidation in the thermal spray process is of significance since it affects greatly the corrosion resistance of coatings. In this work, the growth of oxide layers on in-flight Fe-based amorphous powders in high velocity air fuel (HVAF) thermal spray process was studied in detail by means of numerical and experimental methods. An oxidation model, based on the Lagrangian manner, was used to track the Fe-based amorphous particles. The simulation results showed that the increment of oxide layer thickness was codetermined by oxygen partial pressure of in-flight particles and particle temperature. It occurred primarily in the combustion chamber and barrel rather than the outflow field stage after flame flow. Furthermore, the relationship between in-flight particle oxidation and spray parameters was predicted by simulation. The optimal combustion chamber pressure is 90 psi and the optimal oxygen fuel ratio is 2.95. These were verified by the microstructural feature of in-flight collected particles, and low-oxidation Fe-based amorphous coating was obtained by HVAF utilizing the predicted spray parameters. This work offers us beneficial guidance of fabricating low-defect amorphous metallic coating.

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Data Availability

The raw/processed data required to reproduce these findings are available from the corresponding author upon request.

Abbreviations

\(A_{0}\) :

Model constant \(\left( {{\text{A}} \cdot {\text{s}}^{ - 1} } \right)\)

\(C_{{\text{D}}}\) :

Drag coefficient

\(C_{{\text{p}}}\) :

Specific heat capacity \(\left( {{\text{J}} \cdot {\text{kg}}^{ - 1} \cdot {\text{K}}^{ - 1} } \right)\)

\(d_{{\text{p}}}\) :

Diameter of particle (m)

E :

Enthalpy \(\left( {{\text{J}} \cdot {\text{kg}}^{ - 1} } \right)\)

f :

Solid fraction

g :

Gravitational acceleration \(\left( {{\text{m}} \cdot {\text{s}}^{ - 1} } \right)\)

h :

Convective heat transfer coefficient \(\left( {{\text{W}} \cdot {\text{m}}^{ - 2} \cdot {\text{K}}^{ - 1} } \right)\)

H :

Total heat transfer coefficient \(\left( {{\text{W}} \cdot {\text{m}}^{ - 2} \cdot {\text{K}}^{ - 1} } \right)\)

\(H_{{{\text{ox}}}}\) :

Heat of oxidation \(\left( {{\text{J}} \cdot {\text{kg}}^{ - 1} } \right)\)

\(H_{{{\text{sf}}}}\) :

Latent heat \(\left( {{\text{J}} \cdot {\text{kg}}^{ - 1} } \right)\)

k :

Thermal conductivity \(\left( {{\text{W}} \cdot {\text{m}}^{ - 1} \cdot {\text{K}}^{ - 1} } \right)\)

\(k_{{\text{b}}}\) :

Boltzman constant

\(k_{{\text{g}}}\) :

Thermal conductivity of gas \(\left( {{\text{W}} \cdot {\text{m}}^{ - 1} \cdot {\text{K}}^{ - 1} } \right)\)

\(k_{{{\text{ox}}}}\) :

Thermal conductivity of oxide layer \(\left( {{\text{W}} \cdot {\text{m}}^{ - 1} \cdot {\text{K}}^{ - 1} } \right)\)

\(k_{{\text{s}}}\) :

Thermal conductivity of particle \(\left( {{\text{W}} \cdot {\text{m}}^{ - 1} \cdot {\text{K}}^{ - 1} } \right)\)

\(k_{0}\) :

Model constant \(\left( {{\text{eV}} \cdot {\text{Torr}}^{ - 0.5} } \right)\)

\({\text{N}}_{{\text{u}}}\) :

Nusselt number

p :

Pressure (Pa)

Pr:

Prandtl number

\(P_{{{\text{O}}_{2} }}\) :

Partial pressure of O2 (Torr)

\(q_{{\text{h}}}\) :

External heat source

Q :

Model constant (eV)

r :

Spherical coordinate

Re:

Reynolds number

s :

Surface area of a sphere having the same volume as the particle

S :

Actual surface area of the particle

\(\Delta t\) :

Time step (s)

T :

Temperature (K)

\(T_{{\text{g}}}\) :

Gas temperature (K)

\(T_{{\text{k}}}\) :

Melting temperature of the primary element (K)

\(T_{{\text{L}}}\) :

Liquidus temperature (K)

\(T_{{\text{s}}}\) :

Solidus temperature (K)

u :

Velocity

\(\Delta x\) :

Gird nodes distance (m)

\(\alpha\) :

Thermal diffusivity \(\left( {{\text{m}}^{2} \cdot {\text{s}}^{ - 1} } \right)\)

\(\beta\) :

Ratio between solid and liquid concentration

Г :

Total energy (internal + kinetic)

\(\delta\) :

Oxide layer thickness (A)

\(\mu\) :

Coefficient of viscosity \(\left( {{\text{N}} \cdot {\text{m}}^{ - 2} {\text{s}}^{ - 1} } \right)\)

\(\rho\) :

Density \(\left( {{\text{kg}} \cdot {\text{m}}^{ - 1} } \right)\)

\(\tau\) :

Deviatoric stress tensor

\(\psi \left( T \right)\) :

Correction function

g:

Gas

i, j, l:

Co-ordinate indices

ox:

Oxide

p:

Particle

R:

Particle radius

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Acknowledgments

This work was supported by the National Natural Science Foundation of China (Nos. U1908219, 52171163), the Key Research Program of the Chinese Academy of Sciences (No. ZDRW-CN-2021-2-2), Natural Science Foundation of Liaoning Province (No. 2022-MS-364), Educational Commission of Liaoning Province of China (No. L2020021), Fushun Revitalization Talents Program (No. FSYC202107011).

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Authors and Affiliations

  1. Shenyang National Laboratory for Materials Science, Institute of Metal Research, CAS, Shenyang, 110016, People’s Republic of China

    Nian-Chu Wu, Fan Yang, Wen-Hai Sun, Yan Liang, Suo-De Zhang & Jian-Qiang Wang

  2. School of Mechanical Engineering, Liaoning Petrochemical University, Fushun, 113001, People’s Republic of China

    Nian-Chu Wu & Guang Yang

  3. School of Materials Science and Engineering, University of Science and Technology of China, Shenyang, 110016, People’s Republic of China

    Fan Yang

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  1. Nian-Chu Wu
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Wu, NC., Yang, F., Sun, WH. et al. In-Flight Oxidation of Fe-Based Amorphous Particle During HVAF Spraying: Numerical Simulation and Experiment. J Therm Spray Tech 32, 2187–2201 (2023). https://doi.org/10.1007/s11666-023-01623-0

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