Abstract
A three-dimensional two-way coupled Eulerian-Lagrangian scheme is used to simulate suspension high-velocity oxy-fuel spraying process. The mass, momentum, energy, and species equations are solved together with the realizable k-ε turbulence model to simulate the gas phase. Suspension is assumed to be a mixture of solid particles [mullite powder (3Al2O3·2SiO2)], ethanol, and ethylene glycol. The process involves premixed combustion of oxygen-propylene, and non-premixed combustion of oxygen-ethanol and oxygen-ethylene glycol. One-step global reaction is used for each mentioned reaction together with eddy dissipation model to compute the reaction rate. To simulate the droplet breakup, Taylor Analogy Breakup model is applied. After the completion of droplet breakup, and solvent evaporation/combustion, the solid suspended particles are tracked through the domain to determine the characteristics of the coating particles. Numerical simulations are validated against the experimental results in the literature for the same operating conditions. Seven or possibly eight shock diamonds are captured outside the nozzle. In addition, a good agreement between the predicted particle temperature, velocity, and diameter, and the experiment is obtained. It is shown that as the standoff distance increases, the particle temperature and velocity reduce. Furthermore, a correlation is proposed to determine the spray cross-sectional diameter and estimate the particle trajectories as a function of standoff distance.
Similar content being viewed by others
References
P. Fauchais, G. Montavon, R.S. Lima, and B.R. Marple, Engineering a New Class of Thermal Spray Nano-Based Microstructures from Agglomerated Nanostructured Particles, Suspensions and Solutions: An Invited Review, J. Phys. D, 2011, 44(9), p 093001
P. Fauchais, G. Montavon, and G. Bertrand, From Powders to Thermally Sprayed Coating, J. Therm. Spray Technol., 2009, 19, p 56-80
P. Fauchais and G. Montavon, Latest Developments in Suspension and Liquid Precursor Thermal Spraying, J. Therm. Spray Technol., 2009, 19, p 226-239
L. Pawlowski, Suspension and Solution Thermal Spray Coatings, Surf. Coat. Technol., 2009, 203, p 2807-2829
A. Klilinger, R. Gadow, G. Mauer, A. Guignard, R. Vaben, and D. Stover, Review of New Developments in Suspension and Solution Precursor Thermal Spray Processes, J. Therm. Spray Technol., 2011, 20, p 677-695
J. Oberste Berghaus, J.G. Legoux, C. Moreau, R. Hui, C. Deces-Petit, W. Qu, S. Yick, Z. Wang, R. Maric, and D. Ghosh, Suspension HVOF Spraying of Reduced Temperature Solid Oxide Fuel Cell Electrolytes, J. Therm. Spray Technol., 2008, 17, p 700-707
S. Moghtadernejad, M. Tembely, M. Jadidi, N. Esmail, and A. Dolatabadi, Shear Driven Droplet Shedding and Coalescence on a Superhydrophobic Surface, Phys. Fluids, 2015, 27, p 032106
S. Moghtadernejad, M. Mohammadi, M. Jadidi, M. Tembely, and A. Dolatabadi, Shear Driven Droplet Shedding on Surfaces with Various Wettabilities, SAE Int. J. Aerosp., 2013, 6, p 459-464
S. Moghtadernejad, M. Jadidi, M. Tembely, and A. Dolatabadi, Shear driven rivulet dynamics on surfaces with various wettabilities, Proceedings of ASME 2014 International Mechanical Engineering Congress and Exposition, Montreal, Nov 14-20, 2014
S. Moghtadernejad, M. Jadidi, M. Tembely, N. Esmail, and A. Dolatabadi, Concurrent Droplet Coalescence and Solidification on Surfaces with Various Wettabilities, J. Fluids Eng., 2015, 137, p 071302
S. Moghtadernejad, M. Jadidi, N. Esmail, and A. Dolatabadi, Shear-Driven Droplet Coalescence and Rivulet Formation, Proc. Inst. Mech. Eng. Part. C J. Mech. Eng. Sci., 2015, doi:10.1177/0954406215590186
S. Moghtadernejad, “Dynamics of Droplet Shedding and Coalescence under the Effect of Shear Flow”, Ph.D. Thesis, Concordia University, Montreal, 2014
A. Vardelle, C. Moreau, N.J. Themelis, and C. Chazelas, A Perspective on Plasma Spray Technology, Plasma Chem. Plasma Process., 2015, 35, p 491-509
P. Fauchais, R. Etchart-Salas, V. Rat, J.F. Coudert, N. Caron, and K. Wittmann-Teneze, Parameters Controlling Liquid Plasma Spraying: Solutions, Sols, or Suspensions, J. Therm. Spray Technol., 2008, 17(1), p 31-59
J. Fazilleau, C. Delbos, V. Rat, J.F. Coudert, P. Fauchais, and B. Pateyron, Phenomena Involved in Suspension Plasma Spraying Part 1: Suspension Injection and Behavior, Plasma Chem. Plasma Process., 2006, 26(4), p 371-391
F.L. Toma, L.M. Berger, D. Jacquet, D. Wicky, I. Villaluenga, Y.R. de Miguel, and J.S. Lindelov, Comparative Study on the Photocatalytic Behaviour of Titanium Oxide Thermal Sprayed Coatings from Powders and Suspensions, Surf. Coat. Technol., 2009, 203, p 2150-2156
A. Killinger, M. Kuhn, and R. Gadow, High-Velocity Suspension Flame Spraying (HVSFS), a New Approach Foe Spraying Nanoparticles with Hypersonic Speed, Surf. Coat. Technol., 2006, 201, p 1922-1929
R. Gadow, A. Killinger, and J. Rauch, New Results in High Velocity Suspension Flame Spraying (HVSFS), Surf. Coat. Technol., 2008, 202, p 4329-4336
R. Gadow, A. Killinger, and J. Rauch, Introduction to High-Velocity Suspension Flame Spraying (HVSFS), J. Therm. Spray Technol., 2008, 17, p 655-661
M. Jadidi, S. Moghtadernejad, and A. Dolatabadi, A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray, Coatings, 2015, 5(4), p 576-645
L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, 2nd ed., Wiley, Chichester, 2008
A. Dolatabadi, J. Mostaghimi, and V. Pershin, Effect of a Cylindrical Shroud on Particle Conditions in High Velocity Oxy-Fuel Spray Process, Sci. Technol. Adv. Mater., 2002, 3, p 245-255
J.D. Anderson, Jr., Modern Compressible Flow with Historical Perspective, 2nd ed., McGraw-Hill, Singapore, 1990
M.L. Norman and K.A. Winkler, Supersonic Jets, Los Alamos Science, New Mexico, 1985
S.R. Turns, An Introduction to Combustion, Concepts and Applications, 2nd ed., McGraw-Hill, Boston, 2000
C.T. Crowe, M. Sommerfeld, and Y. Tsuji, Multiphase Flows with Droplets and Particles, CRC Press, Boca Raton, 1998
M. Taleby and S. Hossainpour, Numerical Investigation of High Velocity Suspension Flame Spraying, J. Therm. Spray Technol., 2012, 21, p 1163-1172
E. Gozali, S. Kamnis, and S. Gu, Numerical Investigation of Combustion and Liquid Feedstock in High Velocity Suspension Flame Spraying Process, Surf. Coat. Technol., 2013, 228, p 176-186
E. Gozali, M. Mahrukh, S. Gu, and S. Kamnis, Numerical Analysis of Multicomponent Suspension Droplets in High-Velocity Flame Spray Process, J. Therm. Spray Technol., 2014, 23, p 940-949
E. Dongmo, A. Killinger, M. Wenzelburger, and R. Gadow, Numerical Approach and Optimization of the Combustion and Gas Dynamics in High Velocity Suspension Flame Spraying (HVSFS), Surf. Coat. Technol., 2009, 203, p 2139-2145
E. Dongmo, R. Gadow, A. Killinger, and M. Wenzelburger, Modeling of Combustion as Well as Heat, Mass, and Momentum Transfer During Thermal Spraying by HVOF and HVSFS, J. Therm. Spray Technol., 2009, 18, p 896-908
J. Oberste Berghaus and B.R. Marple, High-Velocity Oxy-Fuel (HVOF) Suspension Spraying of Mullite Coatings, J. Therm. Spray Technol., 2008, 17, p 671-678
ANSYS Inc., ANSYS FLUENT Theory Guide, 2011
H. Tabbara and S. Gu, A Study of Liquid Droplet Disintegration for the Development of Nanostructured Coatings, AIChE J., 2012, 58, p 3533-3544
S. Kamnis and S. Gu, 3-D Modelling of Kerosene-Fuelled HVOF Thermal Spray Gun, Chem. Eng. Sci., 2006, 61, p 5427-5439
S. Gordon and B.J. McBride, Computer Program for Calculation of Complex Chemical Equilibrium Compositions and Applications, NASA Reference Publication No. 1311 (Lewis Research Center, Cleveland, OH, Oct 5, 1994)
F. Jabbari, M. Jadidi, R. Wuthrich, and A. Dolatabadi, A Numerical Study of Suspension Injection in Plasma-Spraying Process, J. Therm. Spray Technol., 2014, 23, p 3-13
G.E. Lorenzetto and A.H. Lefebvre, Measurements of Drop Size on a Plain-Jet Airblast Atomizer, AIAA J., 1977, 15, p 1006-1010
E. Quijada-Maldonado, G.W. Meindersma, and A.B. de Haan, Viscosity and Density Data for the Ternary System Water(1)-Ethanol(2)-Ethylene Glycol(3) Between 298.15 K and 328.15 K, J. Chem. Thermodyn., 2013, 57, p 500-505
C.C. Goodson, “Simulation of Microwave Heating of Mullite Rods,” M.Sc. Thesis, Virginia Polytechnic Institute and State University, VA, 1997
H. Schneider, K. Okada, and J.A. Pask, Mullite and Mullite Ceramics, Wiley, Chichester, 1994
B. Hildmann and H. Schneider, Heat Capacity of Mullite: New Data and Evidence for a High-Temperature Phase Transformation, J. Am. Ceram. Soc., 2004, 8(2), p 227-234
S. Azizian and M. Hemmati, Surface Tension of Binary Mixtures of Ethanol + Ethylene Glycol from 20 to 50 °C, J. Chem. Eng. Data, 2003, 48, p 662-663
S. Tanvir and L. Qiao, Surface tension of Nanofluid-Type Fuels Containing Suspended Nanomaterials, Nanoscale Res. Lett., 2012, 7, p 226
B.W. Brian and J.C. Chen, Surface Tension of Solid-Liquid Slurries, AIChE J., 1987, 33(2), p 316-318
G.I. Taylor, The Shape and Acceleration of a Drop in High-Speed Air Stream, The Scientific Papers of Sir Geoffrey Ingram Taylor, Vol 3, G.K. Batchelor, Ed., Cambridge University Press, Cambridge, 1963, p 457-464
M. Li and P.D. Christofides, Modeling and Control of High-Velocity Oxygen-Fuel (HVOF) Thermal Spray: A Tutorial Review, J. Therm. Spray Technol., 2009, 18, p 753-768
M. Li and P.D. Christofides, Computational Study of Particle In-Flight Behavior in the HVOF Thermal Spray Process, Chem. Eng. Sci., 2006, 61, p 6540-6552
M. Li and P.D. Christofides, Multi-Scale Modeling and Analysis of an Industrial HVOF Thermal Spray Process, Chem. Eng. Sci., 2005, 60, p 3649-3669
A. Dolatabadi, J. Mostaghimi, and V. Pershin, High efficiency nozzle for thermal spray of high quality, low oxide content coatings. U.S. Patent Number 6,845,929, 2005
S. Basu and B.M. Cetegen, Modeling of Liquid Ceramic Precursor Droplets in a High Velocity Oxy-Fuel Flame Jet, Acta Mater., 2008, 56, p 2750-2759
M. Jadidi, M. Mousavi, S. Moghtadernejad, and A. Dolatabadi, A Three-Dimensional Analysis of the Suspension Plasma Spray Impinging on a Flat Substrate, J. Therm. Spray Technol., 2015, 24, p 11-23
G. Mauer, R. Vaßen, and D. Stover, Comparison and Applications of DPV-2000 and Accuraspray-g3 Diagnostic Systems, J. Therm. Spray Technol., 2007, 16, p 414-424
F. Tarasi, “Suspension Plasma Sprayed Alumina-Yttria Stabilized Zirconia Nano-composite Thermal Barrier Coatings: Formation and Roles of the Amorphous Phase,” Ph.D. Thesis, Concordia University, Montreal, 2010
J. Colmenares-Angulo, K. Shinoda, T. Wentz, W. Zhang, Y. Tan, and S. Sampath, On the Response of Different Particle State Sensors to Deliberate Process Variations, J. Therm. Spray Technol., 2011, 20, p 1035-1048
S. Sampath, V. Srinivasan, A. Valarezo, A. Vaidya, and T. Streibl, Sensing, Control, and In Situ Measurement of Coating Properties: An Integrated Approach Toward Establishing Process-Property Correlations, J. Therm. Spray Technol., 2009, 18, p 243-255
F. Bissons, M. Lamontagne, C. Moreau, L. Pouliot, J. Blain, and F. Nadeau, Ensemble In-Flight Particle Diagnostics Under Thermal Spray Conditions, Thermal Spray 2001: New Surfaces for a New Millennium, C.C. Berndt, K.A. Khor, and E.F. Lugscheider, Ed., ASM International, Materials Park, 2001, p 705-714
S. Moghtadernejad, M. Jadidi, N. Esmail, and A. Dolatabadi, SPH Simulation of Rivulet Dynamics on Surfaces with Various Wettabilities, SAE Int. J. Aerosp., 2015, 8(1), p 160-173
M. Gorokhovski and M. Herrmann, Modeling Primary Atomization, Annu. Rev. Fluid Mech., 2008, 40, p 343-366
C.W. Hirt and B.D. Nichols, Volume of Fluid (VOF) Method for the Dynamics of Free Boundaries, J. Comput. Phys., 1981, 39, p 201-225
M. Jadidi, M. Tembely, S. Moghtadernejad, and A. Dolatabadi, A coupled level set and volume of fluid method with application to compressible two-phase flow, Proceedings of 22nd Annual Conference of the CFD Society of Canada, Toronto, June 1-4, 2014
Acknowledgments
The authors would like to acknowledge the support provided by Natural Sciences and Engineering Research Council of Canada (NSERC).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jadidi, M., Moghtadernejad, S. & Dolatabadi, A. Numerical Modeling of Suspension HVOF Spray. J Therm Spray Tech 25, 451–464 (2016). https://doi.org/10.1007/s11666-015-0364-6
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11666-015-0364-6