Time-varying evolutionary mechanism analysis of the multiphase flow during high-velocity oxygen-fuel (HVOF) thermal spraying WC-12Co particle

HVOF thermal spraying with the fuel of aviation kerosene has unique advantages for spraying WC-12Co ceramic particles. The time-varying evolution mechanism of the multiphase flow formed by the particles wrapping with the combustion flame flow is quantitatively revealed, which is essential for preparing of high-quality coatings. In this study, the breakup and gasification process of kerosene droplet was considered. The fuel droplet, flame flow and spraying particles were directly coupled. Based on the computational fluid dynamics (CFD) method, a transient evolution model of HVOF thermal spraying multiphase flow with JP5000 spray gun was established. The Euler-Lagrange method of bidirectional coupling was used to track the continuous and discrete phases. The spraying combustion flame characteristics were expressed by the realizable k-epsilon turbulence model and eddy dissipation model (EDM). The results show that the multiphase coupling transient evolution model quantitatively captures the nonlinear changes of the breaking and gasification for the kerosene droplet, combustion reaction, particle flight behavior and others during spraying. The kerosene droplets in the combustion chamber aggregate with each other to form large droplets, which are rapidly broken and gasified in the peripheral areas. Due to the violent combustion, a gas-phase circulation was formed by the heat and cold air. As the combustion progresses, the flame flow becomes stable and orderly. When particles with a size of 20 to 30 mu m impact the substrate, the particle temperature is close to the solid phase temperature, and the velocity is fast. The particle temperature and velocity decrease with the increase of the particle size.