Experimental and numerical evaluation of the performance of supersonic two-stage high-velocity oxy-fuel thermal spray (Warm Spray) gun

Katanoda, Hiroshi; Morita, Hiromitsu; Komatsu, Masayuki; Katayama, Seiji

doi:10.1007/s11630-011-0440-2

Cited by 14 publications

(2 citation statements)

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“…Warm spray was first patented by Browning [17] and then developed by many researchers [18][19][20][21]. The principles of warm spray are similar to HVOF process.…”

Section: Introductionmentioning

confidence: 99%

Numerical investigation of dual-stage high velocity oxy-fuel (HVOF) thermal spray process: A study on nozzle geometrical parameters

Jafari

Emami

Mahmoudi

2017

Applied Thermal Engineering

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The present study takes the advantage of computational fluid dynamics (CFD) methods to model steady-state, two-dimensional, axisymmetric, turbulent, compressible and combusting flow in a dual-stage high velocity oxy-fuel (HVOF) thermal spray system. The Eulerian method is used to solve the continuum gas phase and the Lagrangian method is utilized for tracking the particles. The effects of particle loads on the continuous gas phase are included in the simulation. Thus, compared to the previous studies, we investigate the influence of coupling between the particle and gas phases in modeling of the dual-stage HVOF process. It is found that decouple modeling of the particle and the continuous phase causes a significant error in velocity of particle at the impact moment, even for low powder particle loading. We further investigate the effects of four geometrical parameters on the behavior of gas phase and consequently the particle phase. Results also show that the turbulent intensity of flow at different sections of the warm spray process is the most important factor determining the radial distribution of nitrogen and temperature in the barrel. It also determines the radial distribution of oxygen in the free jet outside of the barrel. It is further found that reduction of the first nozzle diameter and increasing the length of the divergent section (for a fixed divergent angle) of the convergent-divergent nozzle reduce the particle temperature while these changes do not affect the particle velocity. In other words, changing these geometrical parameters has a desirable effect on the particle temperature without causing an undesirable change on the particle velocity.

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“…Warm spray was first patented by Browning [17] and then developed by many researchers [18][19][20][21]. The principles of warm spray are similar to HVOF process.…”

Section: Introductionmentioning

confidence: 99%

Numerical investigation of dual-stage high velocity oxy-fuel (HVOF) thermal spray process: A study on nozzle geometrical parameters

Jafari

Emami

Mahmoudi

2017

Applied Thermal Engineering

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“…Since the first papers on warm spraying (WS) were published in 2006 (Kawakita et al, 2006a,b), significant efforts have been made to understand its process fundamentals (Yokoyama et al, 2006;Watanabe et al, 2007a;Kuroda et al, 2008;Kim et al, 2008Kim et al, , 2009aKim et al, ,b,c, 2010aKatanoda et al, 2009Katanoda et al, , 2011Kim and Kuroda, 2010) and to explore potential advantages of coatings made by the process for industrial applications (Watanabe et al, 2007b;Kawakita et al, 2008a,b,c;Chivavibul et al, 2008Chivavibul et al, , 2010, out of which a couple review articles have been published . Various thermal spray processes are classified schematically in terms of particles' temperature and velocity on a so-called process map (Sampath et al, 2003;Vaidya et al, 2005;Valarezo et al, 2010) as shown in Figure 7.1.…”

Section: Introductionmentioning

confidence: 99%

Current status and future prospects of warm spray technology☆

Molak¹,

Kim²,

Watanabe³

et al. 2015

Future Development of Thermal Spray Coatings

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Current Status and Future Prospects of Warm Spray Technology

et al. 2011

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A modification of high-velocity oxy-fuel (HVOF) thermal spray process named as warm spray (WS) has been developed. By injecting room temperature inert gas into the combustion gas jet of HVOF, the temperature of the propellant gas can be controlled in a range approximately from 2300 to 1000 K so that many powder materials can be deposited in thermally softened state at high impact velocity. In this review, the characteristics of WS process were analyzed by using gas dynamic simulation of the flow field and heating/acceleration of powder particles in comparison with HVOF, cold spray (CS), and high-velocity air-fuel (HVAF) spray. Transmission electron microscopy of WS and CS titanium splats revealed marked differences in the microstructures stemming from the different impact temperatures. Mechanical properties of several metallic coatings formed under different WS and CS conditions were compared. Characteristics of WC-Co coatings made by WS were demonstrated for wear resistant applications.

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Experimental and numerical evaluation of the performance of supersonic two-stage high-velocity oxy-fuel thermal spray (Warm Spray) gun

Cited by 14 publications

References 6 publications

Numerical investigation of dual-stage high velocity oxy-fuel (HVOF) thermal spray process: A study on nozzle geometrical parameters

Numerical investigation of dual-stage high velocity oxy-fuel (HVOF) thermal spray process: A study on nozzle geometrical parameters

Current status and future prospects of warm spray technology☆

Current Status and Future Prospects of Warm Spray Technology

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