NUMERICAL SIMULATION OF PARTICLE DEPOSITION EFFICIENCY IN HVOF SPRAYING : MATERIALS EFFECT
Keywords:
HVOF, numerical simulation, critical velocity, deposition efficiency
Abstract
Particle critical velocity (for thermally sprayed particles) is not only the threshold for successful deposition of particles, but also a key parameter influencing deposition efficiency and coating quality. High velocity oxy-fuel (HVOF) thermal spraying is a well-established thermal spraying process, which has been extensively used in engineering fields. The coating produced by HVOF boasts the benefits of low porosity, low oxide content, and high adhesion. This study uses WC-Co and 316L stainless steel particles with different thermal conductivities as the spray particles, and develops the corresponding finite element models in Abaqus. A finite element model was developed to investigate two key aspects of HVOF thermal spraying: the relationship between particle critical velocity and particle diameter/temperature, and the influence of intrinsic material property variations on particle critical velocity. Numerical results show that particles with higher temperature and smaller diameter exhibit lower critical velocity and are more likely to form effective bonding with the substrate. Materials featuring high thermal conductivity and low specific heat capacity exhibit better heating capability. The better the heating ability, the more sensitive the material is. It can greatly affect the critical velocity, thereby enhancing the deposition efficiency of particles.
References
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[16] B. Sun, H. Fukanuma, N. Ohno, Study on stainless steel 316L coatings sprayed by a novel high pressure HVOF, Surface and Coatings Technology, 239 (2014), 58-64, doi:10.1016/j.surfcoat.2013.11.018
[17] C. Lyphout, P. Nylén, L. Östergren, Relationships Between Process Parameters, Microstructure, and Adhesion Strength of HVOF Sprayed IN718 Coatings, Journal of Thermal Spray Technology, 20 (2010), 76-82, doi:10.1007/s11666-010-9543-7
[18] A.R.C. Nascimento, F.B. Ettouil, C. Moreau, S. Savoie, R. Schulz, Production of Babbitt Coatings by High Velocity Oxygen Fuel (HVOF) Spraying, Journal of Thermal Spray Technology, 26 (2017), 1732-1740, doi:10.1007/s11666-017-0615-9
[19] W. Tillmann, S. Kuhnt, I.T. Baumann, A. Kalka, E.-C. Becker-Emden, A. Brinkhoff, Statistical Comparison of Processing Different Powder Feedstock in an HVOF Thermal Spray Process, Journal of Thermal Spray Technology, 31 (2022), 1476-1489, doi:10.1007/s11666-022-01392-2
[20] C.M. Hackett. T.C. Hanson, G.S. Settles, Independent Control of HVOF Particle Velocity and Temperature, Journal of Thermal Spray Technology, 11 (2002), 75-85, doi:10.1361/105996302770349005
[21] H. Assadi, F. Gärtner, T. Stoltenhoff, H. Kreye, Bonding mechanism in cold gas spraying, Acta Mater, 51 (2003), 4379-4394, doi:10.1016/s1359-6454(03)00274-x
[22] J.M. Guilemany, V. V. Sobolev, J. C. Garmier and J. A. Calero, Modelling of particle movement and thermal behaviour during, Surface and Coatings Technology, 63 (1994), 181-187, doi:10.1016/0257-8972(94)90096-5
[2] B. Wielage, A. Wank, H. Pokhmurska, T. Grund, C. Rupprecht, G. Reisel, E. Friesen, Development and trends in HVOF spraying technology, Surface and Coatings Technology, 201 (2006), 2032-2037, doi:10.1016/j.surfcoat.2006.04.049
[3] S. Kamnis, S. Gu, 3-D modelling of kerosene-fuelled HVOF thermal spray gun, Chemical Engineering Science, 61 (2006), 5427-5439, doi:10.1016/j.ces.2006.04.005
[4] S. Kamnis, S. Gu, Numerical modelling of propane combustion in a high velocity oxygen–fuel thermal spray gun, Chemical Engineering and Processing: Process Intensification, 45 (2006), 246-253, doi:10.1016/j.cep.2005.06.011
[5] S. Kamnis, S. Gu, T.J. Lu, C. Chen, Numerical modelling of sequential droplet impingements, Journal of Physics D: Applied Physics, 41 (2008), 165303, doi:10.1088/0022-3727/41/16/165303
[6] S. Kamnis, S. Gu, T.J. Lu, C. Chen, Numerical modeling the bonding mechanism of HVOF sprayed particles, Computational Materials Science, 46 (2009), 1038-1043, doi:10.1016/j.commatsci.2009.05.009
[7] A. Srikanth, G. Mohammed Thalib Basha, B. Venkateshwarlu, A Brief Review on Cold Spray, Coating Process, Materials Today: Proceedings, 22 (2020), 1390-1397, doi:10.1016/j.matpr.2020.01.482
[8] G. Liang, C.J. Zhou, Y.X. Liu, Critical Velocity Prediction and Characterization of Bonding Types of High-Velocity, Air-Fuel-Sprayed Titanium Coating on Aluminum Alloys, Coatings, 12 (2022), 234, doi:10.3390/coatings12020234
[9] A. Moridi, S.M. Hassani-Gangaraj, M. Guagliano, A hybrid approach to determine critical and erosion velocities in the cold spray process, Applied Surface Science, 273 (2013), 617-624, doi: 10.1016/j.apsusc.2013.02.089
[10] C.J. Huang, A. List, J.J. Shen, B.L. Fu, S. Yin, T. Chen, B. Klusemann, F. Gärtner, T. Klassen, Tailoring powder strengths for enhanced quality of cold sprayed Al6061 deposits, Materials & Design, 215 (2022), 110494, doi:10.1016/j.matdes.2022.110494
[11] A.M. Vilardell, N. Cinca, S. Dosta, I.G. Cano, J.M. Guilemany, Feasibility of using low pressure cold gas spray for the spraying of thick ceramic hydroxyapatite coatings, International Journal of Applied Ceramic Technology, 16 (2018), 221-229, doi:10.1111/ijac.13088
[12] L. Alonso, M.A. Garrido-Maneiro, P. Poza, A study of the parameters affecting the particle velocity in cold-spray: Theoretical results and comparison with experimental data, Additive Manufacturing, 67 (2023), 103479, doi:10.1016/j.addma.2023.103479
[13] X.M. Wang, F. Feng, M.A. Klecka, M.D. Mordasky, J.K. Garofano, T. El-Wardany, A. Nardi, V.K. Champagne, Characterization and modeling of the bonding process in cold spray additive manufacturing, Additive Manufacturing, 8 (2015), 149-162, doi:10.1016/j.addma.2015.03.006
[14] J. X. Yu, X. Liu, Y. Yu, Z.M. Li, S.B. Xu, H.D. Li, P.F. Liu, L.M. Wang, Effect of HVOF Spraying Process on Particle Behavior of Fe-Based Amorphous Alloy Coatings, Journal of Thermal Spray Technology, 31 (2022), 2448-2462, doi:10.1007/s11666-022-01476-z
[15] H. Ruiz-Luna, D. Lozano-Mandujano, J.M. Alvarado-Orozco, A. Valarezo, C.A. Poblano-Salas, L.G. Trápaga-Martínez, F.J. Espinoza-Beltrán, J. Muñoz-Saldaña, Effect of HVOF Processing Parameters on the Properties of NiCoCrAlY Coatings by Design of Experiments, Journal of Thermal Spray Technology, 23 (2014), 950-961, doi:10.1007/s11666-014-0121-2
[16] B. Sun, H. Fukanuma, N. Ohno, Study on stainless steel 316L coatings sprayed by a novel high pressure HVOF, Surface and Coatings Technology, 239 (2014), 58-64, doi:10.1016/j.surfcoat.2013.11.018
[17] C. Lyphout, P. Nylén, L. Östergren, Relationships Between Process Parameters, Microstructure, and Adhesion Strength of HVOF Sprayed IN718 Coatings, Journal of Thermal Spray Technology, 20 (2010), 76-82, doi:10.1007/s11666-010-9543-7
[18] A.R.C. Nascimento, F.B. Ettouil, C. Moreau, S. Savoie, R. Schulz, Production of Babbitt Coatings by High Velocity Oxygen Fuel (HVOF) Spraying, Journal of Thermal Spray Technology, 26 (2017), 1732-1740, doi:10.1007/s11666-017-0615-9
[19] W. Tillmann, S. Kuhnt, I.T. Baumann, A. Kalka, E.-C. Becker-Emden, A. Brinkhoff, Statistical Comparison of Processing Different Powder Feedstock in an HVOF Thermal Spray Process, Journal of Thermal Spray Technology, 31 (2022), 1476-1489, doi:10.1007/s11666-022-01392-2
[20] C.M. Hackett. T.C. Hanson, G.S. Settles, Independent Control of HVOF Particle Velocity and Temperature, Journal of Thermal Spray Technology, 11 (2002), 75-85, doi:10.1361/105996302770349005
[21] H. Assadi, F. Gärtner, T. Stoltenhoff, H. Kreye, Bonding mechanism in cold gas spraying, Acta Mater, 51 (2003), 4379-4394, doi:10.1016/s1359-6454(03)00274-x
[22] J.M. Guilemany, V. V. Sobolev, J. C. Garmier and J. A. Calero, Modelling of particle movement and thermal behaviour during, Surface and Coatings Technology, 63 (1994), 181-187, doi:10.1016/0257-8972(94)90096-5
Published
2026-04-02
How to Cite
1.
Wang R, Xie Z, Qi X, Wu N. NUMERICAL SIMULATION OF PARTICLE DEPOSITION EFFICIENCY IN HVOF SPRAYING : MATERIALS EFFECT. MatTech [Internet]. 2026Apr.2 [cited 2026Jul.16];60(2):171–178. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1600
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