Numerical Analysis of the Activated Combustion High-Velocity Air-Fuel Spraying Process: A Three-Dimensional Simulation with Improved Gas Mixing and Combustion Mode

Liu, Fuqiang; Li, Zhiyong; Fang, Min; Hou, Hua

doi:10.3390/ma14030657

Cited by 9 publications

(3 citation statements)

References 45 publications

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“…Air is used as a combustion supporting agent. Combining this with the four-step reaction mechanism of propane combustion proposed by Jones [27], it is simplified into a one-step chemical reaction equation as follows [28]:…”

Section: Combustion Reaction Model Of Thermal Sprayingmentioning

confidence: 99%

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The Effect of High-Velocity Air-Fuel WC-12Co Coatings on the Wear and Corrosion Resistance of TC18 Titanium Alloy

et al. 2023

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TC18 titanium alloy is an essential material for aircraft landing gear. To reveal the wear and corrosion mechanisms of landing gear in service, a WC-12Co coating on a TC18 substrate was prepared by High-Velocity Air-Fuel (HVAF) spraying based on optimized process parameters, and an analysis of the microscopic characterization results for the materials involved was performed. Based on the computational fluid dynamics (CFD) method, the combustion reaction and discrete phase models of HVAF spraying were established. The flame characteristics under compressible turbulence and the flight temperature and velocity of particles were calculated. The effect of the spraying parameters on the flight temperature and velocity of particles was evaluated based on the response surface method (RSM) through multiple groups of orthogonal experiments, and the optimized process parameters were determined. The mass flow rate of reactants was 0.051 kg/s, the oxygen/fuel ratio was 2.83, the mass flow rate of the nitrogen was 0.000325 kg/s, the pressure of oxygen and fuel inlet was 1 MPa, the pressure at the particles inlet was 0.6 MPa and the maximum temperature and velocity of spraying particles were 1572 K and 417 m/s, respectively. The coatings prepared with the optimized process were subjected to the Scanning Electron Microscope (SEM), Energy Dispersive Spectroscopy (EDS), X-Ray Diffraction (XRD), wear, hardness, artificial seawater soaking and neutral salt spray experiments. The results showed that the mean hardness of the TC18 substrate was 401.2 HV0.3, the mean hardness of the WC-12Co coating was 1121 HV0.3, the friction coefficient between the TC18 substrate and the Si3N4 ceramic ball was 0.55 and the friction coefficient between the WC-12Co coating and the Si3N4 ceramic ball was 0.4. Compared to the TC18 substrate, the hardness of the WC-12Co coating was increased by 720 HV0.3, the friction coefficient with the Si3N4 ceramic ball decreased by 0.11, the corrosion resistance significantly improved and the maximum depth of the corrosion pits was 5 μm. The properties of the TC18 titanium alloy were effectively improved by the WC-12Co coating. The results of this study provide guidance for surface protection technologies of aircraft landing gear.

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Section: Combustion Reaction Model Of Thermal Sprayingmentioning

confidence: 99%

“…The particles are assumed to have a spherical shape and to not interact with each other. They are mainly subject to drag forces during spraying, and the motion equation of a single particle can be expressed as [28]:…”

Section: Discrete Phase Model Of Particlesmentioning

confidence: 99%

The Effect of High-Velocity Air-Fuel WC-12Co Coatings on the Wear and Corrosion Resistance of TC18 Titanium Alloy

et al. 2023

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“…The simulation domain and turbulent zone (TZ) are depicted in Figure 3 a. Accordingly, the turbulent flow in the TZ area can be defined as [ 32 , 33 ]:

…”

Section: Process Modellingmentioning

confidence: 99%

Effects of Underwater Friction Stir Welding Heat Generation on Residual Stress of AA6068-T6 Aluminum Alloy

et al. 2022

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This article aims to study water-cooling effects on residual stress friction stir welding (FSW) of AA6068-T6 aluminum alloy. For this reason, the FSW and submerged FSW processes are simulated by computational fluid dynamic (CFD) method to study heat generation. The increment hole drilling technique was used to measure the residual stress of welded samples. The simulation results show that materials softening during the FSW process are more than submerged. This phenomenon caused the residual stress of the joint line in the submerged case to be lower than in the regular FSW joint. On the other hand, the results revealed that the maximum residual stresses in both cases are below the yielding strength of the AA6068-T6 aluminum alloy. The results indicated that the residual stress along the longitudinal direction of the joint line is much larger than the transverse direction in both samples.

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Correlation Between Process Parameters and Particle In-flight Behavior in AC-HVAF

Bobzin

Heinemann²,

Jasutyn³

2023

J Therm Spray Tech

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A computational fluid dynamics model for understanding the HVAF process and the influence of the process parameters on the particle flight properties is investigated. Achieving this objective involves a novel approach to modeling the HVAF process with pressure inlet boundary conditions and integration of the mixing chamber. The study comprises the prediction of the flow fields described by a set of equations consisting of continuity, momentum, energy, and species transport. These equations are then solved with realizable k-ε turbulence model, a two-step chemistry model and eddy dissipation model to simulate the combustion reaction. Consequently, the interaction between the CoNiCrAlY alloy particles and the flow is modeled using a Lagrangian approach considering the forces acting on the particles and the heat transfer. The results show that the gas flow field is mainly affected by the compressed air and propane parameters. Furthermore, the flight behavior of the smaller particles is significantly influenced by the gas flow, while the larger particles tend to maintain their momentum and energy. Through the simulation model, an in-depth process understanding of the HVAF process can be achieved. More importantly, the model can be used as a tool for efficient process development.

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Numerical Analysis of the Activated Combustion High-Velocity Air-Fuel Spraying Process: A Three-Dimensional Simulation with Improved Gas Mixing and Combustion Mode

Cited by 9 publications

References 45 publications

The Effect of High-Velocity Air-Fuel WC-12Co Coatings on the Wear and Corrosion Resistance of TC18 Titanium Alloy

The Effect of High-Velocity Air-Fuel WC-12Co Coatings on the Wear and Corrosion Resistance of TC18 Titanium Alloy

Effects of Underwater Friction Stir Welding Heat Generation on Residual Stress of AA6068-T6 Aluminum Alloy

Correlation Between Process Parameters and Particle In-flight Behavior in AC-HVAF

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