Numerical analysis of a high-velocity oxygen-fuel thermal spray system

The fluid and particle flow field characteristics of a high-velocity oxygen-fuel (HVOF) thermal spray (TS) system are analyzed using a two-phase flow model and simulated using computational fluid dynamics (CFD) techniques. The model consists of a conservation equation and constitutive relations for both gas and particle phases. Compressible, turbulent flow is modeled by ak-ɛ turbulent model. A Lagrangian formulation is used to model particle trajectory, and heat and momentum transfer. The fluid velocity fluctuations resulting from gas turbulence are simulated by a stochastic model and the particle motion in the turbulent flow is calculated in a Lagrangian Stochastic-Deterministic (LSD) method. Details of gas flow field, particle temperature and particle velocity histories, and particle temperature and velocity profiles in the system are presented. For the validation of the numerical analysis, the computed results are compared with available experimental measurement. Excellent agreement between simulations and measurements is obtained for both gas and particle flow fields. A parametric study is also conducted for different particle sizes and different nozzle barrel lengths. The flow phenomena for different flow parameters are analyzed and explained as the result of gas dynamics and heat and momentum transfer between the two phases. The developed methodology provides a means to analyze, design, and optimize the TS process. The numerical analysis presents a first comprehensive, fundamental quantitative analysis for the HVOF TS system.