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Tuesday, May 15, 2007 - 4:00 PM

Unsteady 3D Large Eddy Simulation of an Ar-H2 Plasma Jet: Analysis of Initial Resultsng Process

G. Balmigere, CEA Le Ripault, MONTS, France; E. Meillot, CEA Le Ripault, Monts, France; J. P. Caltagirone, S. Vincent, Laboratoire TREFLE, PESSAC, France

The quality of nanocoatings generated by suspension plasma spraying highly depends on the way particle-containing liquid drops are generated and transported throughout the plasma flame. Those are subjected to successive fragmentations, coupled interactions with the turbulent flow field, and phase change (liquid-vapor) phenomena. The numerical simulation provides a useful tool for evaluating the heat and momentum transfers between the drops and the plasma. This study aims at simulating the secondary break-up and the deviation of the liquid drops from their initial path, as they enter the plasma. Depending on the spraying conditions, the liquid droplets may penetrate in the plasma core or simply be expelled outside the hot region. A parametric study involving the surface tension, the viscosity and the density of the suspensions on the one hand and the energy level of the plasma on the other hand, is conducted. Behavior tendencies and most influencing parameters emerge from this study, and might justify simplifying assumptions of further experimental and numerical works. The unsteady Navier-Stokes equations are solved in their turbulent formulation for the simulation of the stationary plasma field in 2D configurations. Suspension drops are directly injected into the plasma and followed in an Eulerian way with the Volume of Fluid method. The simulated deviation and dispersion angles are finally compared to the experimental ones.

Summary: We present 2D simulations of the interaction between a plasma jet and liquid drops, in the suspension plasma spraying process. A parametric study is conducted to determine the influence of the suspension properties and the energy level of the plasma on the deviation and dispersion angles of the droplets.