Three dimensional simulation of HVOF spray deposition of nanoscale materials

We have developed and validated three dimensional simulation capability to model the TS systems' gas and coating powder flow for the TS process analysis, and to illustrate the roots of the TS systems' inefficiencies. The same capability can be used to design optimized TS systems, and to optimize and control the coating process. Examples are given for TS process designs with improved performance and system efficiency. The use of numerical simulation will be especially crucial for plating with nanoscale powders. We will discuss specific equipment and process solutions that will make nanoscale powers coating a viable industrial process. (C) 1997 Acta Metallurgica Inc.