Final Report Summary - SIMUSPRAY (Computational simulation to enhance technology development of thermal spray coating)
Thermal spraying is a versatile technology which enables high-performance coating materials deposited on substrates to provide cost effective solutions for high corrosion- temperature- and abrasion-resistant requirements. The thermophysical process involved in thermal spraying is complicated, the influence of many parameters on final coating makes it difficult to produce coating at constant high quality. A possible solution is to use computer based simulation. The latest models based on computational fluid dynamics (CFD) methods are able to reveal detailed thermophysical history of gas and powder flows, which allows good estimate of coating prior to operation. It is believed that the use of computational tools will stimulate heaper and faster development of coating technology and strengthen the EU competitiveness in global market. The project is supported by the Marie Curie Industry-Academia Partnerships and Pathways of between University of Southampton and PyroGenesis SA to draw together industrial and academic researchers with diverse multi-disciplinary skills and expertise (material engineering, mathematics, process and thermal engineering) and with common interests to solve practical challenges using the state-of-the-art simulation techniques; create a platform for research training and knowledge transfer activities, both within and outside the consortium, crossing inter-sector boundaries; provide researchers with an intensive training-through-research programme as well as a complementary skills training to improve their skills and career perspectives.
The work has been carried out in three workpackages: WP 1-Development of computational models; WP 2-Optimization, fabrication and validation; WP3-Knowledge transfer and dissemination. Steady progress has been made according to the objectives. The following tasks have been completed successfully, namely, Modelling of nanoparticle deposition , Modelling of combustion gas flow in HVOF, Modelling of in-flight particles in HVOF, Modelling of droplet/particle deposition from HVOF gun, Establish correlation between operation parameters and coating quality in HVOF spraying, Optimize HVOF gun design using CFD models, Evaluation of HVOF coating samples in comparison with model predictions. The project has made substantial achievement in term of training researchers, producing high quality research outputs with journal papers, knowledge transfer from academia to industry, and supporting SMEs in manufacturing sector at very difficult time to stimulate manufacturing based economy. The industry-academia partnership has gone beyond the existing partners with good interaction with other external bodys to much enlarged technology base. A range of new technologies have been developed including computatoinal models, new thermal spray processes and new coating composites. This will allow the industrial partner to have a pool of technology for future development and commercialization. Some of the technologies, such as, nanostructured coating, warm and cold gas spraying are readily explored with thermal spray system manufacturers with follow-up actions are underway or planned.
The work has been carried out in three workpackages: WP 1-Development of computational models; WP 2-Optimization, fabrication and validation; WP3-Knowledge transfer and dissemination. Steady progress has been made according to the objectives. The following tasks have been completed successfully, namely, Modelling of nanoparticle deposition , Modelling of combustion gas flow in HVOF, Modelling of in-flight particles in HVOF, Modelling of droplet/particle deposition from HVOF gun, Establish correlation between operation parameters and coating quality in HVOF spraying, Optimize HVOF gun design using CFD models, Evaluation of HVOF coating samples in comparison with model predictions. The project has made substantial achievement in term of training researchers, producing high quality research outputs with journal papers, knowledge transfer from academia to industry, and supporting SMEs in manufacturing sector at very difficult time to stimulate manufacturing based economy. The industry-academia partnership has gone beyond the existing partners with good interaction with other external bodys to much enlarged technology base. A range of new technologies have been developed including computatoinal models, new thermal spray processes and new coating composites. This will allow the industrial partner to have a pool of technology for future development and commercialization. Some of the technologies, such as, nanostructured coating, warm and cold gas spraying are readily explored with thermal spray system manufacturers with follow-up actions are underway or planned.