Multi-scale modeling and analysis of an industrial HVOF thermal spray process
Multi-scale modeling and analysis of an industrial HVOF thermal spray process
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DOI：
10.1016/j.ces.2005.02.043
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发表时间：
2005-07
影响因子：
4.7
通讯作者：
Mingheng Li;P. Christofides
中科院分区：
文献类型：
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作者：
Mingheng Li;P. Christofides
提出了一种混合(确定性/随机性)基本模型，用于描述工业超音速火焰喷涂热喷涂过程中的主要物理化学过程(钻石喷枪，Sulzer Metco，美国纽约州韦斯特伯里)。该模型包括描述气体和颗粒温度和速度演化的连续型微分方程组，以及预测涂层微观结构演化的基于规则的随机模拟器。在气体/颗粒动力学方面，采用重整化群k-ε湍流模型求解雷诺平均和法夫平均的N-S方程和能量平衡方程，用四阶龙格-库塔方法确定颗粒的运动轨迹、温度历史和熔化程度。在微观颗粒沉积过程中，涂层微观组织的形成由Madejski变形模型和控制熔片形成、凝固和涂层生长的几个规律所描述。基于所提出的模型，进行了详细的综合参数分析，研究了关键工艺参数与粒子飞行行为以及由此产生的涂层性能之间的关系。
A hybrid (deterministic/stochastic) fundamental model is proposed for the major physico-chemical processes involved in an industrial HVOF thermal spray process (Diamond Jet hybrid gun, Sulzer Metco, Westbury, NY, USA). The model includes continuum type differential equations that describe the evolution of gas and particle temperature and velocity, and a rule-based stochastic simulator that predicts the evolution of the coating microstructure. Regarding gas/particle dynamics, the Reynolds- and Favre-averaged Navier–Stokes equations and the energy balance equations are solved with the renormalization group (RNG) k–ε turbulence model, and the particle trajectories, temperature histories and melting degrees are determined using the fourth-order Runge–Kutta method. On the microscopic particle deposition process, the formation of coating microstructure is captured by the Madejski deformation model and several rules that govern splat formation, solidification and coating growth. Based on the proposed model, a detailed comprehensive parametric analysis is carried out to study the relationship between the key process parameters and the particle in-flight behavior as well as the resulting coating properties.