Simulation Supported Process Development for the Deposition of MCrAlY Coatings by Means of the AC-HVAF Process

仿真支持通过 AC-HVAF 工艺沉积 MCrAlY 涂层的工艺开发

• 批准号: 437084607
• 负责人: Professorin Dr.-Ing. Kirsten Bobzin
• 金额: --
• 依托单位: Institut für Oberflächentechnik (IOT)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2023-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/437084607?language=en
• 关键词: Simulation; Supported; Process; Development; Deposition

The AC-HVAF process (Activated Combustion High Velocity Air Fuel) is one of the process variants of the thermal spraying. The particle in flight characteristics, such as the particle velocity and temperature, are crucial for the properties of thermally sprayed coatings. The AC-HVAF process can close the gap between the High Velocity Oxygen Fuel (HVOF) and Cold Gas Spraying (CGS) process regarding the particle velocity and temperature. It results in a combination of the particle velocity and temperature that leads to a low porosity and oxide content in the deposited coatings, which makes the AC-HVAF process a potential process for applying high-quality MCrAlY coatings, where M stands for nickel, cobalt or their combination. The reported high energy efficiency of the AC-HVAF process in the literature, due to the high deposition rate and deposition efficiency, is a further advantage of the AC-HVAF process. However, the use of the process is still relatively limited due to a lack of process understanding. The particle in-flight characteristics are determined by the combustion process and the gas flow. The majority of these processes takes place inside the spray gun and nozzle, where direct measurement is difficult. Computational fluid dynamic simulation is an efficient tool for overcoming this difficulty. The aim of this research project is the development of suitable AC-HVAF processes, which enable the deposition of high-quality MCrAlY coatings, with the support of CFD (Computational Fluid Dynamics) simulation. The development of the CFD model begins with the analysis of the spraying processes for a fine and a coarse CoNiCrAlY feedstock material. Different aspects regarding the mashing strategy and the combustion model will be considered. The particle velocity after the nozzle exit will be measured using particle diagnostic systems to validate the developed CFD model. The process parameters will be varied systematically in order to verify the applicability of the model under various process conditions. The model will further be used to develop the spraying processes for NiCoCrAlY feedstock materials, which enable the further validation of the applicability of the CFD model. The model will be thereby, if necessary, further developed. The coating properties –porosity, oxygen content, and roughness – of chosen coatings and their behavior under isotherm conditionings will be investigated to reveal the correlation between the coating properties and the process parameters or the process condition. This investigation enables a profound understanding of the AC-HVAF process.

AC-HVAF工艺（激活的燃烧高速空气燃料）是热喷涂的过程变体之一。飞行特性中的粒子（例如粒子速度和温度）对于热喷涂涂层的性质至关重要。 AC-HVAF工艺可以缩小高速氧燃料（HVOF）与冷气喷涂（CGS）过程之间的差距，该过程涉及粒子速度和温度。它导致粒子速度和温度的组合，导致沉积涂层中的孔隙率和氧化物含量低，这使AC-HVAF过程成为应用高质量MCRALY涂层的潜在过程，其中M代表镍，钴或组合。由于高沉积速率和沉积效率，报道的AC-HVAF过程的高能量效率是AC-HVAF过程的进一步优势。但是，由于缺乏过程的理解，该过程的使用仍然相对有限。粒子在机上特性由组合过程和气流确定。这些过程中的大多数发生在喷枪和喷嘴内，那里很难进行直接测量。计算流体动态模拟是克服这一难度的有效工具。该研究项目的目的是开发合适的AC-HVAF工艺，该工艺能够在CFD（计算流体动力学）模拟的支持下实现高质量McRaly涂层的沉积。 CFD模型的开发始于对精细和粗锥形原料材料的喷涂过程的分析。将考虑有关捣碎策略和混合模型的不同方面。喷嘴出口后的粒子速度将使用粒子诊断系统测量以验证开发的CFD模型。该过程参数将系统地变化，以验证模型在各种过程条件下的适用性。该模型将进一步用于开发尼古地原料材料的喷涂过程，这可以进一步验证CFD模型的适用性。因此，该模型将在必要时进一步开发。将研究所选涂层的涂料特性 - 孔隙度，氧气含量和粗糙度 - 将研究等温条件下的行为，以揭示涂料特性与过程参数或过程条件之间的相关性。这项投资使对AC-HVAF过程有深刻的了解。