Nozzle geometry optimization for cold spray applications by using 3D-CFD calculations
Publication date
2024-04-29
Document type
Konferenzbeitrag
Author
Organisational unit
Conference
International Thermal Spray Conference and Exposition 2024 (ITSC 2024) ; Milan, Italy ; April 29–May 1, 2024
Publisher
ASM International
Book title
Thermal Spray 2024 : Proceedings from the International Thermal Spray Conference
First page
751
Last page
758
Article ID
itsc2024p0751
Part of the university bibliography
✅
Language
English
Abstract
In cold spray, optimum process conditions to accelerate particles vary with different densities and melting temperatures of the materials. Therefore, material-specific nozzle designs are required. In the present study, a nozzle geometry optimization concept based on 3D-CFD simulations was developed to provide a specific nozzle design for a given material. Al6061 and pure copper with mean particle diameters of 40 μm were taken as examples. Together with a design of experiments (DoE) approach, the model seeks for the optimal nozzle geometry. In order to reach the highest particle velocity prior to impact upon the substrate, different geometry parameters were varied, such as the nozzle throat cross section, the aspect ratio, and the nozzle divergent section length. The process gas was nitrogen with set stagnation pressure and temperature of 50 bars and 500 °C. For both materials, the simulation identified nozzle divergent section length as the most influential parameter, followed by the throat cross-section. The aspect ratio must be tuned to avoid over expansion of the gas in the nozzle.
Version
Published version
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Metadata only access