A feature-based model for optimizing HVOF process by combining numerical simulation with experimental verification

Abstract

High velocity oxygen-fuel (HVOF) thermal spraying is an advanced thermal spraying technology involving a controlled complex physicochemical phenomenon process with parameters. Optimizing the process while considering interwoven multidisciplinary aspects is a non-trivial research challenge. This paper proposes a close-loop optimization model for the process based on a sophisticated numerical simulation method on in-flight flame/particle behaviors. The advanced feature-based CAD/CFD integration technology is used to construct a theoretical framework in order to further develop a core multiple-view and yet integrated model covering numerical modeling, numerical analysis, and parameter optimization, where the simulation intent can be associated with the optimization intent. A prototype environment has been developed to model the HVOF system configurations, working conditions, and then derive optimal process parameters. To validate the modeling method, an actual HVOF spray system depositing WC-12Co coating was modeled. The optimal process parameters generated by the model were implemented in the HVOF spray system and its coating properties were tested experimentally to verify the model effectiveness.