Mathematical modelling of high velocity oxygen fuel thermal spraying of nanocrystalline materials: an overview

An emerging application of nanocrystalline materials involves the deposition of nanocrystalline coatings using high velocity oxygen fuel (HVOF) thermal spraying. Since the physical, mechanical, and chemical characteristics of a nanocrystalline coating are critically influenced by the HVOF operating parameter, mathematical modelling is increasingly being used to establish a fundamental understanding of the process, to maximize coating performance, and to minimize the amount of experimentation required. In this paper, the modelling of HVOF thermal-spray processes, including combustion, gas dynamics, momentum, and thermal transfer between the particle and gas phase, as well as the impact of particles onto a substrate is reviewed. Particular attention is paid to topics that are particularly relevant to the thermal spraying of nanocrystalline coatings.