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. In a conventional thermal spray system such as plasma, high velocity oxygen fuel (HVOF), or cold spray, coating particles with a size of tens of microns are fed into the spray nozzle where they are heated and accelerated to high velocities. Consequently, thermally sprayed coatings are formed by the impact and solidification of a stream of molten or semi-molten particles on a surface. We 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).