M.Sc.

Thesis Defense

MODELING AND
OPTIMIZATION OF
COMBUSTION ASSISTED
THERMAL SPRAY SYSTEMS
Researcher: Mohammed Khan
Research Advisor: Dr. Tariq
Shamim
RSC Members: Dr. Mohamed
Sassi
Dr. TieJun
Zhang

Outline
Introduction
Motivation
Objectives
Modeling
Results
Conclusions
Future works
2

Introduction
Chrome Plating

Corrosion resistant
Toxic waste - Chromium
ions pollute ground
water and air
Cause cancer and are
human carcinogen
through inhalation
Titanium
coatings
Environmental norms
Excellent corrosion
resistance
High strength to
weight ratio
Sensitive to
temperature

Single Stage High Velocity

Oxygen
Fuel Thermal Spray System

HVOF systems
Jet Kote by Stellar Coatings (gas
fueled)
JP-5000 by Tafa (liquid fueled)
Diamond Jet by Sulzer-Metco
(gas fueled)

Coating formation

Black patches represents pores

SPLAT
Source: http://www.gordonengland.co.uk

Dual Stage Thermal

Spray System

Dual stage spray

Low particle temperature
wide range of particle velocity
7

Previous Work
Kawakita et al. (2008)
liquid fueled HVOF system
Disadvantages
Particle size - 45-150m
Particle temp. Over 2000 K of liquid fueled

system
Costly
liquid fueled HVOF system
Low
Particle size - 30m
deposition
Particle temp. Over 1600 K
efficiency (30 Tabbara et al. (2011)
40%)
liquid fueled HVOF system Low hardness

Kuroda et al. (2008)

Particle size - 30m

Particle temp. Over 1400 K

t much work has been done on modeling of the dual stage

8

Cr

Motivation
Replacement
to
chrome
plating
Use of titanium in aerospace
industry
for landing gear application
Failure of single stage system
to coat
titanium efficiently
Control
over
particle
temperature and oxidation

Objectives
Develop a mathematical model of
dual stage thermal spray system
Study the effect of geometrical
parameters on the gas and particle
phases
Study the effect of operational
parameters on the gas and particle
phases
Observe the effect of important
operational
parameters
on
the
coating properties
10

Modeling Approach
Eulerian

Conservation
of mass,
momentum
and energy

Modeling of
gas flow and
thermal fields

Turbulence
model
Combustion
model

Decoupling
of gas and
particle field
Modeling of
particle
motion,
temperature
and size
distribution
Lagrangian

Laws of motion
Conservation
of energy

11

Assumptions
Main Assumptions

One way coupling due to very low particle

loading
Steady state flow
Chemical equilibrium
Ideal gas assumptions

Assumptions for discrete phase mode

Spherical shape of the particle

Uniform diameter
No interaction between the particles
No temperature gradients (lumped
system)

12

Governing Equations
Gas phase equations
Continuity

Momentum

Energy

Species

Ideal gas equation of state

13

Turbulence modeling
Re-Normalization Group (RNG) k- model
Turbulent kinetic energy

Turbulent kinetic energy dissipation

Combustion modeling

Eddy dissipation model Reactions are infinitely fast

Chemistry

14

Particle phase equations

Particle motion

Particle energy equation

Convective heat transfer
coefficient
Nusselt number

15

Model Setup
Geometry Diamond Jet HVOF
Boundary conditions
All the gas inlets at 300 K
Mass flow rates
Walls are smooth and assumed to be at 350K
boundaries at 1 Mass
atmflow rate
Pressure
Inle Species
t

1
C3H6

O2
2
N2 (Coolant)
Axisymmetric
3
N2 (Carrier gas)
Pressure
basedparticles
solver

MCrAlY

Model parameters

(kg/s)

2.256 x 10-3
6.484 x 10-3
8.604 x 10-3
1.573 x 10-4
5.40 x 10-4

MCrAlY Particles (Co, 32Ni,

21Cr,
8Al, 0.5Y)
SIMPLE
algorithm
Diameter, dp
15 m
order
upwind
scheme
Second
Specific heat, Cp
450 J/kgK
Density, pcriterion 10-6 7900
Convergence
kg/m3

16

Mesh independence test

Mes No. of
h
elemen
ts

60

34121

40

46694

30

60887

76764

94202

101674

113260

133938

156320

50

Terror

20
10
0
0
-10

100000

200000

Number of cells

17

Model Validation

*A. Dolatabadi, et al., "Effect of a cylindrical shroud on particle conditions in high velocity oxy-fuel (HVOF)
18
spray process," Journal of Materials Processing Technology, vol. 137, pp. 214-224, 2003.

Modeling of Dual Stage System

Geometry
Boundary conditions
Titanium particles
Mesh
Titanium Particles
Diameter, dp
Specific heat, Cp
Density, p
Thermal conductivity, kp
[a]-Fuel/Oxygen
[b]-Combustion
Melting Point
inlet
chamber

15 m
544.25 J/kgK
4850 kg/m3
7.44 W/mK
1943
K
[c]-Converging
nozzle

[d]-Coolant inlet

[e]-Mixing chamber

[f]-Converging-diverging
nozzle

[g]-Powder inlet

[h]-Barrel

[i]-Ambient
19

RESULTS AND
DISCUSSION

20

Dual Stage System Base case

articles
articlesunaffected
unaffectedby
byshocks
shocksdue
dueto
tohigh
highmass
massinertia
inertia
articles
articleshave
havelow
lowtemperature
velocity and and
hence
hence
continue
continue
to incre
to i
21

 Effect of Geometrical Parameters

Combustion chamber length
Converging nozzle diameter
Mixing chamber length
Diverging section diameter
Combustion chamber diameter
Converging nozzle length
Mixing chamber diameter
Diverging section length

Effect of Operating Parameters

Coolant mass flow rate
Fuel/Oxygen ratio
Particle size
Reactants mass flow rate
Preheating of reactants

Optimization Study

22

GEOMETRICAL
PARAMETERS

23

Combustion Chamber Length

ncrease in length increases heat transfer and friction

24

Converging Nozzle Exit Diameter

Increase in diameter increases velocity and temperat

25

Mixing Chamber Length

ncrease in length increases heat transfer and friction

26

Diverging Section Diameter

27

OPERATIONAL
PARAMETERS

28

Coolant Mass Flow Rate

High coolant flow rate has high velocity outside nozzl

29

Coolant Mass Flow Rate

Increase in coolant flow rate reduces temperature

30

Fuel Oxygen Ratio

Rich mixtures have high velocities

31

Fuel Oxygen Ratio

Rich mixtures have high temperatures

32

Particle Size

Smaller particles have higher velocities and temperat

33

OPTIMIZATION

34

Optimization
Purpose of Design of Experiments
- Compare the relative effects
- Observe the effects
- Find the optimum parameters
Terminology
- Factors
- Levels
- Response Variable
35

Design of Experiment
Factors and Levels

Factor

Low
Level

High
Level

Equivalence Ratio

0.8

1.2

Spraying Distance
(mm)

380

560

60

120

Powder Feed Rate

Responses (g/min)

Porosity
- Corrosion resistance
Corrosion potential
Corrosion current density
-

Factorial
Design at 95% confidence level
Gil, L. and M. H. Staia (2002). "Influence of HVOF parameters on the corrosion
36
resistance of NiWCrBSi coatings." Thin Solid Films 420421(0): 446-454.

Experimental Data
Equivalen
spraying
ce ratio
distance (mm)

PFR
(g/min)

Porosity
(%)

1.2

380

60

0.57

1.2

380

120

0.36

0.8

380

60

0.27

1.2

560

60

1.31

0.8

560

120

0.5

0.8

380

120

0.66

1.2

560

120

1.18

0.8

560

60

0.5

E_corr
i_corr
(V)
(muA/cm2)
0.313
8.41
0.476
18.67
0.388
11.22
0.473
18.55
0.507
90.55
0.541
60.6
0.415
19.64
0.492
30.99

37

Porosity
500

Hold Values
Powder Feed Rate (g/min)

475

Porosity (%)
< 0.35
0.35 0.40
0.40 0.45
0.45 0.50
0.50 0.55
0.55 0.60
> 0.60

110

60

450
425

Powder Feed Rate (g/ min)

525

100

Hold Values
Spraying Distance (mm)

90

80

70
400
0.8

0.9

1.0
1.1
Equivalence ratio

60
0.8

1.2

120

Porosity
(%)
< 0.5
0.5 0.6
0.6 0.7
0.7 0.8
0.8 0.9
> 0.9

110
Powder Feed Rate (g/ min)

Spraying Distance (mm)

120

Porosity
(%)
< 0.4
0.4 0.6
0.6 0.8
0.8 1.0
1.0 1.2
> 1.2

550

100

Hold Values
Equivalence ratio 1

90

80

0.9

1.0
1.1
Equivalence ratio

1.2

Porosity depends
on all the three
factors

70

60

400

425 450
475 500 525
Spraying Distance (mm)

550

38

380

Corrosion Potential
500

Hold Values
Powder Feed Rate (g/min)

E_corr (V)
< -0.55
-0.55 -0.50
-0.50 -0.45
-0.45 -0.40
-0.40 -0.35
> -0.35

110

60

475
450
425

Powder Feed Rate (g/ min)

525

100

Hold Values
Spraying Distance (mm)

90

80

70
400
0.8

0.9

1.0
1.1
Equivalence ratio

60
0.8

1.2

120

E_corr (V)
< -0.48
-0.48 -0.45
-0.45 -0.42
-0.42 -0.39
-0.39 -0.36
> -0.36

110
Powder Feed Rate (g/ min)

Spraying Distance (mm)

120

E_corr (V)
< -0.50
-0.50 -0.45
-0.45 -0.40
-0.40 -0.35
> -0.35

550

100

Hold Values
Equivalence ratio 1

90

80

70

60

400

425 450
475 500 525
Spraying Distance (mm)

550

0.9

1.0
1.1
Equivalence ratio

1.2

High corrosion
potential
indicates high
corrosion
resistance

39

380

Corrosion Current Density

500

Hold Values
Powder Feed Rate (g/min)

475

I _corr
(muA/cm2)
< 10
10 20
20 30
30 40
40 50
50 60
> 60

110

60

450
425

Powder Feed Rate (g/ min)

525

100

Hold Values
Spraying Distance (mm)

90

80

70
400
0.8

0.9

1.0
1.1
Equivalence ratio

I _corr
(muA/cm2)
< 10
10 20
20 30
30 40
40 50
> 50

110

100

Hold Values
Equivalence ratio 1

90

80

70

60

60
0.8

1.2

120

Powder Feed Rate (g/ min)

Spraying Distance (mm)

120

I _corr
(muA/cm2)
< 10
10 15
15 20
20 25
25 30
> 30

550

400

425 450
475 500 525
Spraying Distance (mm)

550

0.9

1.0
1.1
Equivalence ratio

1.2

Low corrosion
current density
indicates high
corrosion
resistance

40

380

Response Optimization
Goal

Lower

Target

Upper

Porosity

Minimum

0.270

1.310

E_corr

Maximum

-0.541

-0.313

-0.313

I_corr

Minimum

8.410

90.550

Optimum parameters
Equivalence ratio

1.183

Spray Distance

380 mm

Powder Feed Rate

60 g/min

41

Conclusions
The dual stage system can be used to
deposit coatings of temperature sensitive
materials
The combustion chamber length and mixing
chamber length were found to decrease the
gas

and

particle

temperatures

and

velocities
The gas and particle temperatures were
found to increase with converging nozzle
diameter

42

Conclusions (contd.)
Reactant flow rate, fuel/oxygen ratio and
coolant flow rate have significant effect on
the gas and particle phase
Smaller particles have higher temperature
and velocities
Spraying distance and equivalence ratio
were found to influence the porosity and
corrosion resistance

43

FUTURE
WORK
Analyzing the effect of two way coupling
Studying the inflight
titanium particles

behavior

Studying the impact of

distribution on the coating

of

particle

the
size

Studying
the
effects
of
operating
parameters on the thermal and mechanical
properties of the coating

44

ACHIEVEMEN
TS
M.
Khan
and
T.
Shamim,
"Investigation of dual-stage high
velocity oxygen fuel thermal spray
system," in International Conference
on Applied Energy, Pretoria, South
Africa, 2013.
45

ACKNOWLED
GEMENTS
Almighty Allah
My advisor Dr. Tariq Shamim
My RSC members: Dr. Mohamed Sassi and Dr. TieJun
Zhang
My lab colleagues: Dr. Atal Harichandan, Dr. Agus P.
Sasmito, Bilal Hassan, Abhishek Raj, Majed, Alberto,
Victor, and Diego
All Family and friends
Abu Dhabi Govt. and Abu Dhabi Aircraft Technologies
46

Thank you

47