Computational analysis of a three-dimensional high-velocity oxygen fuel (HVOF) thermal spray torch

An analysis of a high-velocity oxygen fuel thermal spray torch is presented using computational fluid dynamics (CFD). Three-dimensional CFD results are presented for a curved aircap used for coating interior surfaces such as engine cylinder bores. The device analyzed is similar to the Metco diamond jet rotating wire torch, but wire feed is not simulated. The feed gases are injected through an axisymmetric nozzle into the curved aircap. Argon is injected through the center of the nozzle. Premixed propylene and oxygen are introduced from an annulus in the nozzle, while cooling air is injected between the nozzle and the interior wall of the aircap. The combustion process is modeled assuming instantaneous chemistry. A standard, two-equation, k-epsilon turbulence model is employed for the turbulent flow field. An implicit, iterative, finite volume numerical technique is used to solve the coupled conservation of mass, momentum, and energy equations for the gas in a sequential manner. Computed flow fields inside and outside the aircap are presented and discussed.