Analysis of two-phase flows for spraying processes

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Thermal sprays are extensively used in the aerospace, automotive, power generation, and biomedical industries to provide protective coatings on landing gear, engine, turbine, and implant components that are exposed to heat, corrosion, and wear. High Velocity Oxygen Fuel (HVOF) has been demonstrated to be one of the most efficient techniques to deposit high performance coatings. I have designed and built a shroud attachment which considerably expands the capabilities of the HVOF process in the areas of deposition efficiency and flexibility to allow coating with ceramic powders (U.S. Patent No. 6,845,929). In this work, we would like to further expand the capabilities of the process by facilitating the injection and deposition of nanosized coating particles using a suspension feedstock. For this purpose, we need to have a thorough understanding of the atomization and liquid fragmentation in all speed gas flow regimes. The proposed work will address this need through computational and experimental studies. Axial and radial suspension injections will be modeled and characterized to address the need of industries for spraying nanopowders at moderate cost