Numerical approach and optimization of the combustion and gas dynamics in High Velocity Suspension Flame Spraying (HVSFS)

The interest in submicron and nano-structured layers applied by thermal spray technologies on different surfaces has been significantly increased during the last decade. Conventional HVOF spraying processes are not suitable to achieve submicron and nano-particles. Therefore, High Velocity Suspension Flame Spraying (HVSFS) has been developed for the processing of nano-structured spray material to achieve dense surface layers in supersonic mode with a refined micro- or nano-structure, from which superior mechanical and physical properties are expected. However. the chemical and thermodynamic phenomena occurring in the HVSFS reacting flow field are a challenging, multidisciplinary issue. This study is intended to analyze and understand the HVSFS combustion and flow dynamic system on the basis of a CFD model and numerical calculation. The final aim is an optimization of the process parameters by variations during simulation experiments. (C) 2009 Elsevier B.V. All rights reserved.