A Numerical Study of Suspension Injection in Plasma-Spraying Process

Jabbari, Farzad; Jadidi, Majid; Wüthrich, Rolf; Dolatabadi, Ali

doi:10.1007/s11666-013-0030-9

Cited by 46 publications

(49 citation statements)

References 22 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…RSM has been used to simulate the thermal spray processes as well. Comparison between RSM and k-ε models shows the superior performance of RSM [50]. For more information about RSM model see reference [47].…”

Section: Governing Equationsmentioning

confidence: 99%

A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray

2015

View full text Add to dashboard Cite

Abstract:In thermal spraying processes, molten, semi-molten, or solid particles, which are sufficiently fast in a stream of gas, are deposited on a substrate. These particles can plastically deform while impacting on the substrate, which results in the formation of well-adhered and dense coatings. Clearly, particles in flight conditions, such as velocity, trajectory, temperature, and melting state, have enormous influence on the coating properties and should be well understood to control and improve the coating quality. The focus of this study is on the high velocity oxygen fuel (HVOF) spraying and high velocity suspension flame spraying (HVSFS) techniques, which are widely used in academia and industry to generate different types of coatings. Extensive numerical and experimental studies were carried out and are still in progress to estimate the particle in-flight behavior in thermal spray processes. In this review paper, the fundamental phenomena involved in the mentioned thermal spray techniques, such as shock diamonds, combustion, primary atomization, secondary atomization, etc., are discussed comprehensively. In addition, the basic aspects and emerging trends in simulation of thermal spray processes are reviewed. The numerical approaches such as Eulerian-Lagrangian and volume of fluid along with their advantages and disadvantages are explained in detail. Furthermore, this article provides a detailed review on simulation studies published to date. OPEN ACCESSCoatings 2015, 5 577

show abstract

Section: Governing Equationsmentioning

confidence: 99%

A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray

2015

View full text Add to dashboard Cite

show abstract

“…To verify the numerical code LAVA-P-3D for the plasma spray process, the centerline gas temperature profiles were calculated and compared with published numerical results (Jabbari et al, 2014) and experimental data (Brossa and Pfender, 1988) in Fig. 4.…”

Section: Validation Of Model Predictionsmentioning

confidence: 99%

“…The deviation between experiment and our modeling result is within 10%. Both experiment and simulation used the Sulzer 3MB plasma gun with the same operating parameters as in reference (Jabbari et al, 2014). Fig.…”

Section: Validation Of Model Predictionsmentioning

confidence: 99%

See 1 more Smart Citation

Dynamic modeling of micro- and nano-sized particles impinging on the substrate during suspension plasma spraying

Zhang

Xiong

Shao

2016

J. Zhejiang Univ. Sci. A

View full text Add to dashboard Cite

Suspension plasma spraying (SPS) can be utilized to manufacture finely structured coatings. In this process, liquid suspended with micro-or nano-sized solid particles is injected into a plasma jet. It involves droplet injection, solvent evaporation, and discharge, acceleration, heating, and melting of the solid particles. The high-speed and high-temperature particles finally impact on the substrate wall, to form a thin layer coating. In this study, a comprehensive numerical model was developed to simulate the dynamic behaviors of the suspension droplets and the solid particles, as well as the interactions between them and the plasma gas. The plasma gas was treated as compressible, multi-component, turbulent jet flow, using Navier-Stokes equations solved by the Eulerian method. The droplets and solid particles were treated as discrete Lagrangian entities, being tracked through the spray process. The drag force, Saffman lift force, and Brownian force were taken into account for the aerodynamic drag force, aerodynamic lift force, and random fluctuation force imposed on the particles. Spatial distributions of the micro-and nano-sized particles are given in this paper and their motion histories were observed. The key parameters of spray distribution, including particle size and axial spray distance, were also analyzed. The critical size of particle that follows well with the plasma jet was deduced for the specified operating conditions. Results show that in the downstream, the substrate influences the flow field structure and the particle characteristics. The appropriate spray distances were obtained for different micro-and nano-sized particles.

show abstract

“…However, particle behavior in SPPS, especially during atomization and evaporation, are still under deep exploration. Some numerical work has focused on the droplet or particle behaviors from the perspective of the scale effect in the plasma gas flow and the physical model of droplets and particles [14][15][16]. However, these studies often ignore the thermal effects in the atomization of the liquid feedstock and the droplets or, if they consider this effect, overlook the flash evaporation of the droplet.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Droplet Atomization and Evaporation in Solution Precursor Plasma Spray Coating

Xiong

Sun

2017

Coatings

View full text Add to dashboard Cite

Solution precursor plasma spray (SPPS) is a novel and promising technique in producing nanostructured coatings. This technique involves complex heat, mass and momentum transfer among the liquid feedstock, droplets, plasma jet and the coating material. Nevertheless, the droplet atomization and evaporation in the plasma jet is one of the most essential parts to obtain the desired coating architecture. In the present work, a three-dimensional two-way-coupled Eulerian-Lagrangian code is used to simulate the interactions between the solution precursor and plasma. In order to obtain a more realistic understanding regarding droplet atomization and vaporization, the flash-boiling effect is modeled by an improved vaporization model. This model could provide accurate details for the droplet pyrolysis and help to optimize the solution precursor plasma spray process. We show that the fragmentation of the liquid stock and its vaporization mainly dominate the spraying details and can be decisive to the coating quality. We further investigate their role in SPPS and separately probe their inner link with the flow field relating to the distinctive area when droplets are flying through the thermal flow field. Our studies reveal that ethanol droplets, compared to those of water, show a superior characteristics in SPPS, owing to the low boiling point and low surface tension, conducive to the evaporation and atomization of droplets. In addition, the mixture of the plasma gas with hydrogen breaks the droplets more thoroughly compared to the pure plasma. The numerical results were compared and found to agree well with previous experimental and simulation work.

show abstract

A Numerical Study of Suspension Injection in Plasma-Spraying Process

Cited by 46 publications

References 22 publications

A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray

A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray

Dynamic modeling of micro- and nano-sized particles impinging on the substrate during suspension plasma spraying

Investigation of Droplet Atomization and Evaporation in Solution Precursor Plasma Spray Coating

Contact Info

Product

Resources

About