Abstract The present study introduces and validates a comprehensive numerical model for hydrogen-fueled high-velocity oxygen-fuel (HVOF) spraying of tungsten carbide-cobalt-chromium (WC-Co-Cr) powder. We conduct three-dimensional (3D), two-way coupled simulations of the reactive, particle-laden flow within the DJ2600 thermal spray gun and its supersonic exhaust jet. The model incorporates the real nozzle geometry, applies the eddy-dissipation concept (EDC) as a finite-rate chemistry approach for hydrogen combustion, and uses an explicit algebraic Reynolds stress model (EARSM) for turbulent scales. Consequently, our simulations enable a precise analysis of flame dynamics by revealing unprecedented levels of flow field detail in the nozzle’s convergent section. We find that the interaction of fuel, oxidizer, and cooling air streams produces diverse, three-dimensional flame shapes. Furthermore, we compare the standard particle modeling approach from literature with an enhanced approach that accounts for rarefied flow at the particle scale, viscous heating in the boundary layers around particles, and temperature-dependent particle heat capacities. Our results demonstrate that including these phenomena is critical for correctly predicting particle impact properties. Finally, we analyze particle states both in flight and upon impact on the target surface.
Biller et al. (Mon,) studied this question.
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