Numerical Analysis of High-Velocity Oxygen Fuel Thermal-Spray Process for Fe-Based Amorphous Coatings

High-velocity oxygen fuel (HVOF)-sprayed amorphous alloy coatings usually have advantages of a dense structure that improve their resistance to corrosion, wear, and fatigue in the substrate. The flame flow characteristics and particle behaviors during the spray process have a significant influence on the amorphous coating structure and properties. In this study, a computational fluid dynamics model is enforced to analyze the flame flow and Fe-based amorphous alloy particle behavior in an HVOF spray process. The flame flow temperature, velocity characteristics, and the Fe48Cr15Mo14C15B6Y2 Fe-based amorphous alloy particles’ velocities, temperatures, flight trajectories, and mass concentration distribution characteristics are simulated. Moreover, the effects of the oxygen/fuel ratio, particle morphology parameter, particle-injection rate, and angle on the particle behavior are also investigated. Judging from the simulation results, the optimum amorphous alloy particle size varies between 20 and 30 μm, the shape factor is within the range of 0.9–1, the optimum O/F ratio is 3.4, the optimum injection angle is 45°, and the optimum injection rate is 10 m/s. With these conditions, most of the particles settled toward the centerline of the spray gun and are in a semisolid or solid state before affecting the substrate, giving the materials optimal coating structure and performance.

Particle behavior in a turbulent flow within an axially corrugated geometry

In this numerical study particle behavior inside a sinusoidal pipe geometry is analyzed. The 3D geometry consists of three identical modules, with a periodic boundary condition applied to the flow in the stream wise direction. The incompressible, turbulent gas flow is modeled using a Large Eddy Simulation (LES) approach. Furthermore, the particle dynamics are simulated using a Lagrangian point force approach incorporating the Stokes drag and slip correction factor. Four different sizes of particles, corresponding to a Stokes number less than unity, are considered along with two different inflow conditions: continuous and pulsatile. The pulsatile inflow has an associated flow frequency of 80 Hz. The fluid flow through the sinusoidal pipe is characterized by weak flow separation in the expansion zones of the sinusoidal pipe geometry, where induced shear layers and weak recirculation zones are identified. Particle behavior under the two inflow conditions is quantified using particle dispersion, particle residence time, and average radial position of the particle. No discernible difference in the particle behavior is observed between the two inflow conditions. As the observed recirculation zones are weak, the particles are not retained within the cavities for a long duration of time, thereby reducing their likelihood of agglomerating.

Development of Simpler Coarse-Grain Model for Analyzing Behavior of Particles in Fluid Flow

A new simpler coarse-grain model (SCG) for analyzing particle behaviors under fluid flow in a dilute system, by using a discrete element method (DEM), was developed to reduce calculation load. In the SCG model, coarse-grained (CG) particles were enlarged from original particles in the same way as the existing coarse-grain model; however, the modeling concept differed from the other models. The SCG model focused on the acceleration by the fluid drag force, and the CG particles’ acceleration coincided with that of the original particles. Consequently, the model imposed only the following simple rule: the product of particle density and squared particle diameter is constant. Thus, the model had features that can be easily implemented in the DEM simulation to comprehend the modeled physical phenomenon. The model was validated by comparing the behaviors of the CG particles with the original particles in the uniform and the vortex flow fields. Moreover, the usability of the SCG model on simulating real dilute systems was confirmed by representing the particle behavior in a classifier. Therefore, the particle behavior in dilute particle-concentration systems would be analyzed more simply with the SCG model.

Effect of the Spray Parameters on the Particle Behavior and the Coating Properties During ID Warm Spraying of Fine WC-12Co Powders (-10 + 2 μm)

Internal diameter (ID) coating by means of thermal spraying for the wear and corrosion protection of components is currently experiencing growing interest in science and industry. While high-kinetic spray processes (such as HVOF, HVAF or warm spraying) in combination with cermet materials (e.g. WC-Co or Cr3C2-NiCr) are well established for this purpose in traditional coating of external OD (outer diameter) surfaces, they have hardly been used in the ID (internal diameter) area so far. Even though a few special ID spray guns with compact design and low combustion energy are by now available on the market, only little is known about the effects and interactions of the spray parameters on the particle behavior and the coating properties. Due to the mentioned gun specifications and the usually required short spray distances for ID coating, fine spray powders < 15 μm must be used to ensure sufficient melting and acceleration of the particles. In this study warm spraying of fine WC-12Co powders (-10 + 2 μm) using a novel spray gun “ID RED” (Thermico, Germany) was investigated. Statistical design of experiments (DoE) was employed to analyze and to model the influence of varying spray parameter settings on the in-flight particle behavior and the corresponding coating properties.

Could there be no wave-particle duality, but only waves?

Here, the concept of a wave-particle duality is questioned. First, the experimental proofs existing, respectively, for particles and waves are examined. In the case of particles, no experimental evidence can be found which establishes them; it seems that particles have always been taken for granted. In the case of waves, considerable evidence has accumulated with results on diffraction, interference, and self-interference of larger and larger objects. Then an important remark is made concerning the fact that unlike particles, waves are not observation-dependent: waves existed before observation otherwise the patterns of diffraction or interference would not have been appearing; the wave nature does not depend on the making of a measurement, there is no measurement problem for waves. Consequently, since waves are not observation-dependent, if the objects are demonstrated to be waves, they are only waves. This fact, along with some other evidence, disagrees with the current interpretation of the Wheeler-type delayed-choice experiments, where the absence of interference is interpreted as a particle behavior. Finally, recent works regarding the de Broglie‐Bohm theory are presented, which lead to suggest a new wave-only version of this theory. It is concluded that a wave-only view might be worth considering instead of the wave-particle duality view which has prevailed so far.