Abstract No.:
3731

 Scheduled at:
Thursday, May 22, 2014, Hall H3 9:40 AM
Modeling & Simulation 1


 Title:
Design of experiment oriented fluid simulation for the virtual improvement of the air-cap configuration in arc spraying

 Authors:
Mohamed Abdulgader* / University of Dortmund, Germany
Wolfgang Tillmann / Institute of Materials Engineering, University of Dortmund, Germany

 Abstract:
The computational fluid dynamic approach is adopted in this work, using central composite design, to study the effect of different atomization gas outlet configurations on the gas velocity, jet divergence, and pressure distribution at cap outlet, as well as the generated share stresses on the wire tips. The variables, which are integrated in this study, are primary and secondary atomization gas pressure (PG and SG) as process parameters. The other variables in this study are the size, and the position throat outlet, and the number, and angle of the secondary gas outlet holes. The effect of the process variables and geometrical design variations are analyzed on the obtained gas flow characteristics. Increasing the number of the SG outlet holes leads to higher gas velocities at cap outlet. PG shows the highest effect on the obtained gas velocity. Furthermore, the increased PG led to plume of two separated flow cores caused by the interfering wires. The number of the SG holes and the SG outlet angle has a direct effect on the plume divergence. An increase in SG outlet angle leads to a decrease of the gas velocity. In all air-caps configurations studied, the spraying wires deflected the flow of the primary gas and diverted the cross section shape of the spraying cone from circle to an oval form. The use of Design of Experiment (DoE) in the optimization of the air-cap design by implementing CFD-simulation was proved to be very useful and efficient tool to design high performance air-caps of twin-wire arc-spraying.

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