Studying the Effect of the Air-Cap Configuration in Twin-Wire Arc-Spraying Process on the Obtained Flow Characteristics Using Design of Experiment Oriented Fluid Simulation

Tillmann, Wolfgang; Abdulgader, M.; Anjami, Nassir; Hagen, Leif

doi:10.1007/s11666-014-0183-1

Cited by 4 publications

(4 citation statements)

References 13 publications

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“…Both temperature and velocity are related to the level of splats flattering, related consequently to the hardness. The obtained dependencies agree with the results of previous studies [4,7,8,9].…”

Section: Resultssupporting

confidence: 92%

“…There are many papers focusing on studying the deposition parameter-microstructure-properties relationships for high kinetic processes such as HVOF, HVOF, or for plasma-based spray processes, such as APS. In the case of TWAS technology, the number of studies, focusing on the optimization of deposition process parameters, are rather limited [4][5][6][7][8][9]. On the basis of these works, it can be assumed that although the connection between the microstructure and properties of the coatings and the technological parameters of TWAS deposition is not as direct as it is with other, more controllable spraying technologies, there are clear connections valid for different types of materials.…”

mentioning

confidence: 99%

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Twin Wire Arc Sprayed Coatings for Power Industry Applications – process parameters optimization study

Houdková,

Šulcová,

Lencová

et al. 2023

J. Phys.: Conf. Ser.

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TWAS technology is established and widely used in practice for spraying metal alloy-based coatings, benefiting from the low cost of the device and the mobility, enabling the application of the coatings even on large structures without the need for disassembly. TWAS coatings properties and performance depends not only on the chosen type of the material but also on the deposition process parameters, which must be carefully chosen so that the properties of the resulting coating meet expectations. This paper presents the results of the spraying parameters optimization study, obtained using the multiparametric regression statistic model. 16 different composition of metal wires were included in the study. The results of the statistical analysis are supported by the microstructural analysis, carried out using optical microscopy. The compressed air pressure and the current were identified as significant variable, influencing the coating hardness and deposition rate.

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Section: Resultssupporting

confidence: 92%

mentioning

confidence: 99%

Twin Wire Arc Sprayed Coatings for Power Industry Applications – process parameters optimization study

Houdková,

Šulcová,

Lencová

et al. 2023

J. Phys.: Conf. Ser.

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“…On the one hand, due to the electrode phenomena (e.g., arc, magnetohydrodynamics, and eddies), the TWAS process is associated with an increased spray plume divergence across the spray axis behind the intersection point of the electrode tips. The spray plume characteristics were discussed by numerous authors [2,[51][52][53][54][55][56][57][58]. On the other hand, limitations of the robot dynamics (depending on the path planning strategy) can lead to deviating spray angles and velocities (e.g., gun velocities) along the robot's path [52].…”

Section: Coating Depositionmentioning

confidence: 99%

Process Parameter Settings and Their Effect on Residual Stresses in WC/W2C Reinforced Iron-Based Arc Sprayed Coatings

2017

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Abstract:Residual stresses have been a major source of concern, as they are an inevitable consequence of manufacturing and fabrication processes. The magnitude of these stresses is often as high as, or at least, comparable to the yield strength of the material. In terms of arc sprayed coatings, the utilization of bore hole drilling methods presents some practical disadvantages as mechanical parameters (Poisson's ratio, Young's modulus) need to be identified in order to determine the residual stress distribution. Curvature techniques using Almen strips are cost-and time-effective methods that can be used for analytical quality assurance. Within the scope of this work, a quantitative study of the amount of residual stresses induced in a twin wire arc spraying (TWAS) process for a given combination of process parameters was conducted using the incremental bore hole drilling method, as well as the curvature method including Almen strips. Therefore, the effect of the primary gas pressure, substrate preheating temperature, and handling parameters, such as the spray angle and gun velocity, which influence the coating deposition as well as the heat input into the substrate, are examined. The experiments were carried out by using an iron-based cored wire with cast tungsten carbides as filling. The results of both methods are in an acceptable accordance with each other. Different stress fields were observed depending on the parameter settings.

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“…Thus, Steffens [14], has demonstrated that a higher velocity of the gas flow, produces finer particles and implicitly a higher acceleration, offering the possibility of obtaining some dense deposits, with high mechanical properties. The research carried out to obtain qualitative deposits, directed to increasing the sprayed particles velocity, were performed by using of high spraying pressures [15,16,17] or by projecting some systems of spraying nozzles which can assure a form convergent -divergent of the spraying jet [18,19]. However, for the same purpose, there have been researches in the direction of maintaining high temperature of the particles throughout the spraying jet [20].…”

Section: Introductionmentioning

confidence: 99%

Influence of Process Parameters and Geometry of the Spraying Nozzle on the Properties of Titanium Deposits Obtained in Wire Arc Spraying

Toma

Ioniţă

Gheorghiu

et al. 2015

AMR

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Influence of the process parameters and geometry of the spraying nozzle on the properties of titanium deposits obtained in wire arc spraying. Wire arc spraying is a process in which through minor modifications of the spray parameters, they can have a major impact on the coatings properties. In this paper there is presented a study on the influence of process parameters and fluid dynamics of the atomization gas on the properties of titanium deposits (14T - 99.9% Ti). For this there were used three different frontal spraying nozzles, having different geometries, and were varied the spraying gas pressure and the electrical current on three levels. There were evaluated the particles velocity, coating density, chemical composition and characteristic interface between deposition and substrate. Obviously, the high speed of the atomization gas determinate the improving of all properties, but in the same time increased the oxide content in the layer. However, the oxidation can be drastically reduced if the melting and atomization of the wire droplets is produced at the point of formation of the electric arc, and the spraying jet is designed to constrain the electric arc. The assessment of deposits adherence allowed the observation of process parameters that contribute to its improvement.

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Studying the Effect of the Air-Cap Configuration in Twin-Wire Arc-Spraying Process on the Obtained Flow Characteristics Using Design of Experiment Oriented Fluid Simulation

Cited by 4 publications

References 13 publications

Twin Wire Arc Sprayed Coatings for Power Industry Applications – process parameters optimization study

Twin Wire Arc Sprayed Coatings for Power Industry Applications – process parameters optimization study

Process Parameter Settings and Their Effect on Residual Stresses in WC/W2C Reinforced Iron-Based Arc Sprayed Coatings

Influence of Process Parameters and Geometry of the Spraying Nozzle on the Properties of Titanium Deposits Obtained in Wire Arc Spraying

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