Particle Behavior During the Arc Spraying Process with Cored Wires

Abstract

To use the manifold possibilities that arc spraying offers to deposit wear resistance layers, knowledge of the particle formation and their behavior is necessary. This work is focused on studying the particle properties during arc spraying with cored wires. Different cored wires under various spraying parameters are investigated by means of a high speed camera. Particle properties in-flight, such as velocity and temperature, are determined. Correlation between particle behavior and particle characteristics at different spraying conditions is established. At the same time, the particle-laden gas flow is simulated numerically and the computed solutions are used to illustrate the utility of the proposed CFD model and compared with experimental results. The employed mathematical model represents a system of macroscopic conservation laws for the continuous gas phase and for the gas-solid mixture. This approach formulation makes it possible to circumvent the numerical difficulties associated with the implementation of a (potentially ill-posed) two-fluid model. The discretization in space is performed using a highresolution finite element scheme based on algebraic flux correction in terms of local characteristic variables. The artificial diffusion operator is constructed on the discrete level and fitted to the local solution behavior using a multidimensional flux limiter of TVD type.

Supervision and Measuring of Particle Parameters During the Wire-Arc Spraying Process with the Diagnostic Systems Accuraspray-g3 and LDA (Laser-Doppler-Anemometry)

“…The lower the gas flow rate, the larger the particles and lower the particle velocities are. The same conclusion was drawn by Pormousa et al (Ref 10) and Planche et al (Ref 13) using a DPV 2000 system during twin arc spraying of carbon steel and stainless steel wires, respectively, as well as by Tillmann et al employing an Accuraspray-g3 system (Ref [14][15][16]. The experiments and diagnostic measurements by means of DPV2000 showed no significant influence of wire feed rate and operating arc voltage on particle size (Ref 10).…”

“…The evaluation of particle velocity and temperature during twin wire arc spraying was also carried out using cored wires by means of Accuraspray-g3 (Ref [14][15][16]. Independent of the kind of wires used the highest particle acceleration took place from the point of arc ignition up to a 50 mm stand-off distance, while at stand-off distances between 100 and 150 mm the velocity reached its highest value.…”

Fabrication of Porous Aluminum Coating by Cored Wire Arc Spray for Anchoring Antifouling Hydrogel Layer

“…4 c- e). It is worth noting that the pore size of the porous coatings is smaller than that of the original NaCl powders, which may be due to the fact that NaCl powder was atomized or broken in the high-speed air flow during the spraying process (Ref 41 , 42 ). The pores within the porous Al coating are irregular, which is likely due to the irregular shape of the NaCl particles.…”

Effect of Bond-Layer on the Wear Resistance of a Martensitic Stainless Steel Coating Obtained by Wire Arc Spray

“…Coatings can be formed if the melted fused projectile can deform at the shocks with the substrate. Wire Arc Spray Process (WASP)is one of several technics which consist on being two wires consumable arc electrodes, are drawn from spools and form a liquid droplet due to arc heating [6][7][8][9][10]. The droplet is blown by the atomizing gas.…”