This work presents the nanostructured coating formation using suspension thermal spraying through the HVOF torch. The nanostructured coating formation requires nanosize powder particles to be injected inside a thermal spray torch using liquid feedstock. The liquid feedstock needs to be atomized when injected into the high-velocity oxygen fuel (HVOF) torch. This paper presents the effects of angular injection and effervescent atomization of the liquid feedstock on gas and droplet dynamics, vaporization rate, and secondary breakup in the high-velocity suspension flame spray (HVSFS) process. Different angular injections are tested to obtain the optimum value of the angle of injection. Moreover, effervescent atomization technique based on twin-fluid injection has been studied to increase the efficiency of the HVSFS process. Different solid nanoparticle concentrations in suspension droplets are considered. In angular injection the droplets are injected into the core of the combustion zone; this immediately evaporates the droplets, and evaporation is completed within the torch. The value of 10°–15° is selected as the optimal angle of injection to improve the gas and droplet dynamics inside the torch, and to avoid the collision with the torch's wall. The efficiency of the effervescent atomization can be enhanced by using high gas-to-liquid mass flow rate ratio, to increase the spray cone angle for injecting the suspension liquid directly into the combustion flame. It is also found that the increment in the nanoparticle concentration has no considerable effects on the droplet disintegration process. However, the location of evaporation is significantly different for homogeneous and non-homogeneous droplets

This article reports numerical investigations of turbulent flow field and heat transfer performance of water-alumina nanofluid jet impingement. The jet impinges over a flat, circular heated surface from a circular pipe of diameter $D_{jt}$. The influence of jet Reynolds number (1,200 ≤ ${Re}_{jt}$ ≤ 40,000), jet-outlet-to-target wall distance (2 ≤ $H/D_{jt}$ ≤ 12.8), and particle volumetric concentration (0 ≤ φ ≤ 10%) on the fluid flow and heat transfer are examined. The results of fluid flow and heat transfer are compared with the published experimental data. It is found that the heat transfer increases with increasing values of the particle volumetric concentration while the flow field and turbulent kinetic energy distribution remain unchanged with the inclusion of nanoparticles. About 28% enhancement in stagnation Nusselt number is observed at low values of nanoparticle volumetric concentration (φ = 0.1%) and in the Reynolds number range of 29,000–40,000. For jet-outlet-to-target wall spacing $H/D_{jt}$ values used in the current study, the local Nusselt number distributions vary according to Nu ∝ ${Re}_{jt}^{2/3}$. Numerical simulations are performed using Reynolds-averaged Navier–Stokes method with the shear stress transport k-ω model in commercial CFD code ANSYS-CFX.

This paper presents the effects of the concentration of solid nanoparticles in the liquid feedstock injection on the high-velocity suspension flame spray (HVSFS) process. Four different concentrations of solid nanoparticles in suspension droplets with various droplet diameters are used to study gas dynamics, vaporization rate, and secondary breakup. Two types of injections, viz. surface and group, are used. The group-type injection increases the efficiency of droplet disintegration and the evaporation process and reduces the gas cooling. The initiation of the fragmentation process is difficult for small droplets carrying a high concentration of nanoparticles. Also, smaller droplets undergo rapid vaporization, leaving clogs of nanoparticles in the middle of the barrel. For larger droplets, severe fragmentation occurs inside the combustion chamber. For a higher concentration of nanoparticles, droplets exit the gun without complete evaporation. The results suggest that, in coating applications involving a higher concentration of nanoparticles, smaller droplet sizes are preferred.

The feasibility of a new processing method solution precursor high-velocity oxygen fuel spray (SP-HVOFS) is presented for the production of dense ZrO₂-based nanostructured coatings, in which organometallic chemical precursor droplets are injected into the HVOF spray system. With the help of developed computational fluid dynamics (CFD) solver (Fluent), the evolution of particle volume, area, and number concentration is simulated considering nucleation, coagulation, and sintering. The aerosol model is validated with the experimental data available in the literature. When the oxygen-fuel gas flow rate (GFR) is increased, the (i) velocity and (ii) enthalpy of the HVOF flame is increased. The former reduces the particle residence time in the HVOF flame while the latter favors the sintering. Overall the results show that, by controlling the GFR, single scale nanometre particles (∼1–5 nm) can be fabricated without any agglomeration.