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<p>High-Velocity Oxygen Fuel (HVOF) thermal spraying is widely used to produce high-performance coatings, and numerical modeling provides a practical approach for analyzing flame and particle interactions and process optimization. In this study, a comprehensive numerical model of a JP-5000 HVOF system was developed based on non-premixed combustion. The combustion characteristics of hydrogen, methane, and propane were systematically compared. The influence of the mean mixture fraction was examined to identify an appropriate operating range, including fuel-rich conditions characterized by a lower oxidizer-to-fuel ratio. The effects of particle injection position on particle behavior were also investigated. The coupled influence of spray distance and powder feed rate was evaluated by combining numerical predictions with experimental porosity measurements of WC-12Co coatings. The results indicate that hydrogen produces higher flame temperatures and gas velocities than hydrocarbon fuels. The mean mixture fraction exhibits a nonlinear influence on particle thermokinetic behavior. Axial particle injection enhances particle heating and acceleration compared with radial injection. Spray distance and powder feed rate interact to affect coating porosity.</p>

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Numerical Investigation of Flame Characteristics and Particle Behavior in HVOF Thermal Spraying Using a Non-premixed Combustion Model

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Zhaomiao Liu,
  • Jiale Fan,
  • Yan Pang,
  • Xiang Wang

摘要

High-Velocity Oxygen Fuel (HVOF) thermal spraying is widely used to produce high-performance coatings, and numerical modeling provides a practical approach for analyzing flame and particle interactions and process optimization. In this study, a comprehensive numerical model of a JP-5000 HVOF system was developed based on non-premixed combustion. The combustion characteristics of hydrogen, methane, and propane were systematically compared. The influence of the mean mixture fraction was examined to identify an appropriate operating range, including fuel-rich conditions characterized by a lower oxidizer-to-fuel ratio. The effects of particle injection position on particle behavior were also investigated. The coupled influence of spray distance and powder feed rate was evaluated by combining numerical predictions with experimental porosity measurements of WC-12Co coatings. The results indicate that hydrogen produces higher flame temperatures and gas velocities than hydrocarbon fuels. The mean mixture fraction exhibits a nonlinear influence on particle thermokinetic behavior. Axial particle injection enhances particle heating and acceleration compared with radial injection. Spray distance and powder feed rate interact to affect coating porosity.