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Finite Element Modeling and Analysis of Powder Stream in Low Pressure Cold Spray Process

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Abstract

Low pressure cold gas dynamic spray (LPCGDS) is a coating process that utilize low pressure gas (5–10 bars instead of 25–30 bars) and the radial injection of powder instead of axial injection with the particle range (1–50 μm). In the LPCGDS process, pressurized compressed gas is accelerated to the critical velocity, which depends on length of the divergent section of nozzle, the propellant gas and particle characteristics, and the diameters ratio of the inlet and outer diameters. This paper presents finite element modeling (FEM) of powder stream in supersonic nozzle wherein adiabatic gas flow and expansion of gas occurs in uniform manner and the same is used to evaluate the resultant temperature and velocity contours during coating process. FEM analyses were performed using commercial finite volume package, ANSYS CFD FLUENT. The results are helpful to predict the characteristics of powder stream at the exit of the supersonic nozzle.

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Abbreviations

LPGDS:

Low pressure gas dynamic spray

FEM:

Finite element modeling

CGDS:

Cold gas dynamic spray

CFD:

Computational fluid dynamics

Di :

Inlet diameter

De :

Outlet diameter

Dt :

Throat diameter

Lu :

Convergent length

Ld :

Divergent section length

A, B, C, D, E, F, G, H:

Key points for nozzle

Ωf :

Fluid region

Ωe :

Typical element

ρ g :

Density of the gas

δij :

Components of the identity tensor (Kronecker delta)

v j :

Velocity vector in the jth direction

τ ij :

The stress

g i :

The gravitational acceleration

μ t :

The turbulent viscosity

μ :

The molecular viscosity

k t :

The kinetic energy of turbulence

ε :

The dissipation of kinetic energy of turbulence

ωi :

The weight function

Pi :

Pressure applied at the inlet of the nozzle MPa

x1, x2 :

Variable functions of the position at the axis

χ, α, Ψ :

(Column) vectors of interpolation (shape) functions

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Authors and Affiliations

  1. Shaheed Udham Singh (SUS) College of Engineering and Technology, Tangori, Mohali, 140306, Punjab, India

    Tarun Goyal

  2. Delhi Technological University, New Delhi, 110042, Delhi, India

    Ravinderjit Singh Walia

  3. ISGEC Heavy Engineering Limited, Yamunanagar, 135001, Haryana, India

    Prince Sharma

  4. Shaheed Bhagat Singh State Technical Campus (SBSSTC), Ferozepur, 152004, Punjab, India

    Tejinder Singh Sidhu

Authors
  1. Tarun Goyal
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  2. Ravinderjit Singh Walia
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  3. Prince Sharma
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  4. Tejinder Singh Sidhu
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Correspondence to Tarun Goyal.

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Goyal, T., Walia, R.S., Sharma, P. et al. Finite Element Modeling and Analysis of Powder Stream in Low Pressure Cold Spray Process. J. Inst. Eng. India Ser. C 97, 331–344 (2016). https://doi.org/10.1007/s40032-016-0234-0

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  • DOI: https://doi.org/10.1007/s40032-016-0234-0

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