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Assessment of CFD Modeling via Flow Visualization in Cold Spray Process

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Abstract

The two-phase flow properties of copper particle laden nitrogen are computationally modeled and compared with the data obtained from the experiments, determining the achievable degree of consistency between model and reality. Two common, commercial nozzles are studied. A two-way coupled Lagrangian scheme along with the RSM turbulence model is used to track the particles and to model the interactions between the gas and the particulate phase. Significant agreement is found for the geometrical gas flow structure, the resulting particle velocities, and the dependence of the two-phase flow on the particulate phase mass loading. The particle velocities decrease with increasing mass loading, even for modest powder feed rates of <3 g/s. The velocity drop occurs even when the gas flow rate is kept constant. Adiabatic gas flow models neglecting the energy consumption by the particles are thus inaccurate, except for very dilute suspensions with low technical relevance. For the cases modeled, the experiments evidence the high predictive power of the chosen CFD approach.

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Abbreviations

A :

cross-sectional area of the particle, m2

C D :

drag coefficient

D :

particle diameter, m

F b :

body force, N

Ma :

Mach number

m :

mass, kg

R :

specific gas constant, J/kg K

Re :

Reynolds number

T :

temperature, K

t :

time, s

V :

velocity vector, m/s

ρ:

density, kg/m3

γ:

specific heat ratio

μ:

molecular viscosity, kg/m s

p:

particles

g:

gas

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Acknowledgments

U. Pyritz, F. Heinrichsdorff, and V. Türck are gratefully acknowledged for their contributions to the measurements. A. Dolatabadi would like to thank Natural Sciences and Engineering Research Council of Canada (NSERC).

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Authors and Affiliations

  1. Department of Mechanical & Industrial Engineering, Concordia University, Montreal, QC, Canada

    B. Samareh & A. Dolatabadi

  2. Siemens AG, Corporate Technology, CT MM 5, Siemensdamm 50, 13629, Berlin, Germany

    O. Stier & V. Lüthen

Authors
  1. B. Samareh
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  2. O. Stier
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  3. V. Lüthen
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  4. A. Dolatabadi
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Correspondence to A. Dolatabadi.

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Samareh, B., Stier, O., Lüthen, V. et al. Assessment of CFD Modeling via Flow Visualization in Cold Spray Process. J Therm Spray Tech 18, 934–943 (2009). https://doi.org/10.1007/s11666-009-9363-9

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  • DOI: https://doi.org/10.1007/s11666-009-9363-9

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