Modeling of liquid ceramic precursor droplets in a high velocity oxy-fuel flame jet

Production of coatings by high velocity oxy-fuel (HVOF) flame jet processing of liquid precursor droplets can be an attractive alternative method to plasma processing. This article concerns modeling of the thermophysical processes in liquid ceramic precursor droplets injected into an HVOF flame jet. The model consists of several sub-models that include aerodynamic droplet break-up, heat and mass transfer within individual droplets exposed to the HVOF environment and precipitation of ceramic precursors. A parametric study is presented for the initial droplet size, concentration of the dissolved salts and the external temperature and velocity field of the HVOF jet to explore processing conditions and injection parameters that lead to different precipitate morphologies. It is found that the high velocity of the jet induces shear break-up into several lm diameter droplets. This leads to better entrainment and rapid heat-up in the HVOF jet. Upon processing, small droplets (<5 lm) are predicted to undergo volumetric precipitation and form solid particles prior to impact at the deposit location. Droplets larger than 5 lm are predicted to form hollow or precursor containing shells similar to those processed in a DC arc plasma. However, it is found that the lower temperature of the HVOF jet compared to plasma results in slower vaporization and solute mass diffusion time inside the droplet, leading to comparatively thicker shells. These shell-type morphologies may further experience internal pressurization, resulting in possibly shattering and secondary atomization of the trapped liquid. The consequences of these different particle states on the coating microstructure are also discussed in this article. 2008 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.