Abstract
Abstract In this work, CFD simulations are used to evaluate air cap configurations for twin wire arc spraying (TWAS). Investigators employed a design of experiments (DoE) approach to identify air cap parameters with the greatest impact on gas velocity, jet convergence, and pressure distribution. The ones selected for study are the convergence angle, the length and diameter of the throat, and the distance between the air cap outlet and the point where the wires intersect. In all configurations studied, the spray wires deflected the flow of the primary gas and narrowed the cross-section of the plume along one axis. The effects of each air cap parameter are discussed in the paper along with possible design improvements.
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