Computational study and experimental comparison of the in-flight particle behavior for an external injection plasma spray process |
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Authors: | K Remesh S C M Yu H W Ng C C Berndt |
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Affiliation: | (1) School of Mechanical & Production Engineering, Nanyang Technological University, Nanyang Avenue, 639798 Singapore;(2) Department of Materials Science and Engineering, Stony Brook University, 11794-2275 Stony Brook, NY |
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Abstract: | A three-dimensional computational fluid dynamic (CFD) analysis using Fluent V5.4 was conducted on the in-flight particle behavior
during the plasma spraying process with external injection. The spray process was modeled as a steady jet issuing from the
torch nozzle via the heating of the are gas by an electric are within the nozzle. The stochastic discrete model was used for
the particle distribution. The particle temperature, velocity, and size inside the plasma plume at a specified standoff distance
have been investigated. The results show that carrier gas flow rate variation from 2 standard liters per minute (slm) to 4.0
slm can increase the centerline particle mean temperature and mean velocity by 10% and 16%, respectively, at the specified
standoff distance. A further increase of the carrier gas flow rate to 6 slm did not change the particle temperature, but the
particle velocity was decreased by 20%. It was also found that an increase in the total arc gas flow rate from 52 slm to 61
slm, with all other process parameters unchanged, resulted in a 17% higher particle velocity, but 6% lower particle temperature.
Some of these computational findings were experimentally confirmed by Kucuk et al. For a given process parameter setting,
the kinetic and thermal energy extracted by the particles reached a maximum for carrier gas flow rate of about 3.5–4.0 slm. |
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Keywords: | atmospheric plasma spray CFD modeling in-flight diagnostics particle behavior |
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