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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
HVOF systems
Jet Kote by Stellar Coatings (gas
fueled)
JP-5000 by Tafa (liquid fueled)
Diamond Jet by Sulzer-Metco
(gas fueled)
Coating formation
SPLAT
Source: http://www.gordonengland.co.uk
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
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
12
Governing Equations
Gas phase equations
Continuity
Momentum
Energy
Species
13
Turbulence modeling
Re-Normalization Group (RNG) k- model
Turbulent kinetic energy
Combustion modeling
14
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
16
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.
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
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
Optimization Study
22
GEOMETRICAL
PARAMETERS
23
27
OPERATIONAL
PARAMETERS
28
Particle Size
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
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
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)
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
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)
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
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
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
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
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
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