3D time-dependent numerical simulation for atmospheric plasma spraying

Wen, Kui; Liu, Xuezhang; Zhou, Kesong; Liu, Min; Zhu, Hongtao; Huang, Jian; Zhang, Zhongcheng; Huang, Renzhong; Mei, Jie; Yan, Xingchen; Liao, Hanlin

doi:10.1016/j.surfcoat.2018.12.088

Cited by 13 publications

(3 citation statements)

References 37 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In Figure 6 , the calculated plasma jet temperature along the centerline axis are compared with experimental measurements taken from literature [ 55 ] using the same operating conditions (450 A, Ar/H 2 (40/10 lpm)). The calculated temperatures are in good agreement with associated experimental measurements, which allows the validation of our model.…”

Section: Numerical Resultsmentioning

confidence: 99%

Modeling of Advanced Silicon Nanomaterial Synthesis Approach: From Reactive Thermal Plasma Jet to Nanosized Particles

et al. 2022

View full text Add to dashboard Cite

A three-dimensional numerical modelling of a time-dependent, turbulent thermal plasma jet was developed to synthetize silicon nanopowder. Computational fluid dynamics and particle models were employed via COMSOL Multiphysics® v. 5.4 (COMSOL AB, Stockholm, Sweden) to simulate fluid and particle motion in the plasma jet, as well as the heat dependency. Plasma flow and particle interactions were exemplified in terms of momentum, energy, and turbulence flow. The transport of nanoparticles through convection, diffusion, and thermophoresis were also considered. The trajectories and heat transfer of both plasma jet fields, and particles are represented. The swirling flow controls the plasma jet and highly affects the dispersion of the nanoparticles. We demonstrate a decrease in both particles’ velocity and temperature distribution at a higher carrier gas injection velocity. The increase in the particle size and number affects the momentum transfer, turbulence modulation, and energy of particles, and also reduces plasma jet parameters. On the other hand, the upstream flame significantly impacts the particle’s behavior under velocity and heat transfer variation. Our findings open the door for examining thermal plasma impact in nanoparticle synthesis, where it plays a major role in optimizing the growth parameters, ensuring high quality with a low-cost technique.

show abstract

Section: Numerical Resultsmentioning

confidence: 99%

Modeling of Advanced Silicon Nanomaterial Synthesis Approach: From Reactive Thermal Plasma Jet to Nanosized Particles

et al. 2022

View full text Add to dashboard Cite

show abstract

“…As can be seen, there is no modeling of particle behavior on the route from the atomization nozzle to the substrate, in the literature. Several studies on the numerical analysis of the plasma spray process have been carried out, regarding the analysis of the arc dynamics and its effect on the distributions of the temperature and flow field both inside and outside of the torch [34], the deep neural networks that have an excellent ability to express the governing equations of thermal plasmas [35], the deposition behavior and oxidation mechanism of the coatings [36], or a proposed computational approach that can predict the mechanical properties [37]. The results of a numerical simulation based on a 3D (Ansys Fluent 19.0) model and experimental measurements were compared and thus validated the flow-velocity field directly and the distribution of particle mass concentration indirectly in the case of internal rotating plasma spraying (IRPS) coatings [38].…”

Section: Introductionmentioning

confidence: 99%

Numerical Calculation of the Arc-Sprayed Particles’ Temperature in Transient Thermal Field

2022

View full text Add to dashboard Cite

The physical and mechanical properties of the coatings produced by electric arc thermal spraying are closely related to the velocity and temperature of the particles that interact with the substrate surface. Knowing the temperature variation of the sprayed particles allows establishing their aggregation state, respectively determining the spraying distance, so that the state of aggregation of the particles at the impact moment is predominantly liquid. Obviously, when the sprayed particle passes through the spray cone, it cools continuously due to the low and variable temperature of the entrainment gas. This paper aims to determine analytically the thermal behavior of the particles entrained by the gas jet formed at the thermal spraying in an electric arc, depending on the variable temperature, existing along the spraying cone. In this sense, by modeling with finite elements, using the ANSYS program, the temperature inside the spray jet was determined, and by a mathematical model carried out based on the thermal balance equations, the thermal profile of the sprayed particles was determined. The thermal profile demonstrates that their temperature suddenly increases to the solidification temperature, then increases to the melting temperature—due to the latent heat of solidification, after which it decreases to 300 K.

show abstract

“…Gas dynamics of thermal spraying have been largely investigated in regard to the plasma method of atomizing. Wen et al [27] presented the results of investigations of the arc dynamics and its influence on temperature distribution and flow fields inside and outside the heat source. This work confirmed the importance of control over airflows at different types of atomizing.…”

Section: Introductionmentioning

confidence: 99%

Airflow Dynamics and Aluminum Coating Oxidation Behavior under Electric-Arc Spraying with Airflow Pulsations

2021

View full text Add to dashboard Cite

The paper aims to investigate the airflow dynamics of electric-arc spraying (EAS) with airflow pulsation. The study is focused on the dynamic structure of the airflow with an obstacle in the form of crossed electrodes at the steady and the pulsating air supply (with a frequency up to 120 Hz). The work was fulfilled using a computer simulation, the airflow “shadow” photo visualization, and the microstructure characterization of the coatings formed. It was found that when air flows along the crossed electrodes with a gap of 2 mm, a depression zone appears in the flow with a pressure drop from 0.56 MPa to 0.01 MPa. The air pulsation resulted in a change in a flow’s dynamic structure towards an increase in the length of the depression zone, which covers most of the arc, affecting the liquid metal oxidation. It is established that the frequency of a droplet formation should match the frequency of the airflow pulsation to minimize the metal oxidation. With the air pulsating at about 65 Hz, the oxide volume fraction in the aluminum coating was reduced by 3.6 times compared to the steady airflow. EAS with airflow pulsation has the potential for technological cost reduction.

show abstract

3D time-dependent numerical simulation for atmospheric plasma spraying

Cited by 13 publications

References 37 publications

Modeling of Advanced Silicon Nanomaterial Synthesis Approach: From Reactive Thermal Plasma Jet to Nanosized Particles

Modeling of Advanced Silicon Nanomaterial Synthesis Approach: From Reactive Thermal Plasma Jet to Nanosized Particles

Numerical Calculation of the Arc-Sprayed Particles’ Temperature in Transient Thermal Field

Airflow Dynamics and Aluminum Coating Oxidation Behavior under Electric-Arc Spraying with Airflow Pulsations

Contact Info

Product

Resources

About