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Numerical Investigation of High Velocity Suspension Flame Spraying

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Abstract

High-velocity suspension flame spraying (HVSFS) has recently developed as a possible alternative to conventional HVOF-spraying employing liquid suspensions instead of dry powder feedstock enables the use of nanoparticles. From the fluid dynamics point of view, the HVSFS system is complex and involves three-phase (gas, liquid and solid particles) turbulent flow, heat transfer, evaporation of the suspension solvent, chemical reactions of main fuel (propane) and suspension solvent (ethanol) and supersonic/subsonic flow transitions. Computational fluid dynamic techniques were carried out to solve the mass, momentum, and energy conservation equations. The realizable k-ε turbulence model was used to account for the effect of turbulence. The HVSFS process involves two combustion reactions. A primary combustion process is the premixed oxygen-propane reaction and secondary process is the non-premixed oxygen-gaseous ethanol reaction. For each reaction, one step global reaction, which takes dissociations and intermediate reactions into account, was derived from the equilibrium chemistry code developed by Gordon and McBride and eddy dissipation model was used to calculate the rate of reactions based on the transport equations for all species (10 species) mass fractions. Droplets were tracked in the continuum in a Lagrangian approach. In this paper, flow field inside and outside the gun simulated to provide clear and complete insight about the HVSFS processes. Moreover, the effect of some operative parameters (oxy-fuel flow rate, ethanol flow rate, droplets injection velocity and droplets size) on the gas flow field along the centerline and droplets evaporation behavior was discussed.

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Abbreviations

R i,r :

Net rate of production of species i due to reaction r

M w,i :

Molecular weight of species i

N :

Number of chemical species in the system

\( \upnu^{\prime}_{i,r} \) :

Stoichiometric coefficient for reactant i in reaction r

\( \upnu^{\prime\prime}_{i,r} \) :

Stoichiometric coefficient for product i in reaction r

Y P :

Mass fraction of any product species, P

Y R :

Mass fraction of a particular reactant, R

K :

Turbulence kinetic energy

Ε:

Turbulence dissipation rate

ρ:

Mixture density

A :

Empirical constant equal to 4.0

B :

Empirical constant equal to 0.5

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  1. Department of Mechanical Engineering, Sahand University of Technology, Tabriz, Iran

    M. Taleby & S. Hossainpour

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  1. M. Taleby
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  2. S. Hossainpour
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Correspondence to S. Hossainpour.

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Taleby, M., Hossainpour, S. Numerical Investigation of High Velocity Suspension Flame Spraying. J Therm Spray Tech 21, 1163–1172 (2012). https://doi.org/10.1007/s11666-012-9802-x

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  • DOI: https://doi.org/10.1007/s11666-012-9802-x

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