Abstract
A model is presented describing the details of the wire-arc spray process. The model consists of several submodels each treating a different part of the process. A compressible flow model describes the supersonic nozzle flow upstream of the wire tips. The arc is described by a 3-D arc in cross-flow model using different boundary conditions for the cathode and the anode boundary. The resulting temperature and velocity contours serve as upstream boundary for a 2-D turbulent jet model. Particle generation and acceleration is described by treating the initial droplet formation for the anode and the cathode wire separately and then using the resulting particle size and velocity distributions in a secondary break-up model. Comparison with some experimental results show acceptable agreement. This modeling approach may be used for optimization of wire-arc spray equipment.
Similar content being viewed by others
REFERENCES
M. Nakagawa, K. Shimoda, T. Tomoda, M. Koyama, Y. Ishikawa, and T. Nakajima, in Thermal Spray Research and Applications, Proceedings of the 3rd National Thermal Spray Conference, T. F. Bernecki, ed. (ASM International, Ohio; Long Beach, California; May 20-25, 1990), pp. 457–464.
D. J. Varacalle, G. C. Wilson, L. B. Lundberg, D. L. Hale, V. Zanchuck, W. Kratochvil, and G. Irons, in Thermal Spray Science and Technology, Proceedings of the 8th National Thermal Spray Conference, C. C. Berndt and S. Sampath, eds. (ASM International, Ohio; Houston, Texas; September 11-15, 1995), pp. 373–380.
R. W. Smith and R. Novak, PMI 23, 147–155 (1991).
G. V. Candler and R. S. MacCormack, J. Thermophysics Heat Trans. 5, 266–273 (1991).
J. L. Steger and R. F. Warming, NASA-TM-D78605 (1979).
M. Kelkar, N. Hussary, J. Schein, and J. Heberlein, in Thermal Spray: Meeting the Challenges of the 21st Century, Proceedings of the 15th International Thermal Spray Conference, C. Coddet, ed. (ASM International, Ohio; Nice/France; May 25-29, 1998), Vol. 1, pp. 329–324.
M. Kelkar and J. Heberlein, J. Phys. D: Appl. Phys., 33, 2172–2182 (2000).
M. I. Boulos, P. Fauchais, and E. Pfender, Thermal Plasmas: Fundamentals and Applications (Plenum Publishing, New York and London, 1994), Vol. I.
S. V. Patankar, Numerical Transfer and Fluid Flow Heat (Hemisphere, New York, 1980).
K. C. Hsu, K. Etemadi, and E. Pfender, J. Appl. Phys. 54, 1293–1301 (1983).
K. C. Hsu and E. Pfender, J. Appl. Phys., 54, 4359–4366 (1983).
D. M. Benenson, A. J. Baker, and A. A. Cenkner, Jr., IEEE Trans. Power App. Sys. PAS-88, 513–521 (1969).
J. E. Anderson, Progress in Heat and Mass Transfer, D. Irvine, W. Ibele, J. P. Hartnett, and R. Goldstein, eds. (1969), Vol. 2, pp. 419–425.
N. A. Hussary and J. Heberlein, Thermal Spray: Surface Engineering via Applied Research, Proceedings of the 1st International Thermal Spray Conference, C. C. Berndt, ed. (ASM International, Ohio; Montr èal, Qu èbec/Canada; May 8-11, 2000), pp. 737–742.
A. Favre, Journal de Mecanique 4, 361–390 (1965).
J. H. Park, Masters Thesis, University of Minnesota (1998).
W. M. Pun and D. B. Spalding, Rep. No. HTS/76/The Institute of Energy, London, 1985), pp. VIB/1/1–7.
E. Pfender and Y. C. Lee, Plasma Chem. Plasma Process. 5, 211–237 (1985).
P. J. O'Rourke and A. A. Amsden, SAE Paper 872089 (1987).
L.-P. Hsiang and G. M. Faeth, Int. J. Multiphase Flow 18, 635–652 (1992).
D. Crawmer, Private Communication (1997).
Author information
Authors and Affiliations
Rights and permissions
About this article
Cite this article
Kelkar, M., Heberlein, J. Wire-Arc Spray Modeling. Plasma Chemistry and Plasma Processing 22, 1–25 (2002). https://doi.org/10.1023/A:1012924714157
Issue Date:
DOI: https://doi.org/10.1023/A:1012924714157