Numerical modelling of propane combustion in a high velocity oxygen–fuel thermal spray gun

High velocity oxygen–fuel (HVOF) thermal spraying is a relatively new technology compared to other protective coating methods. Powders sprayed by liquid fuel HVOF guns are able to achieve high impact velocities without overheating, which results in superior coatings. A computational fluid dynamic (CFD) model is developed to investigate propane combustion in the process of HVOF thermal spraying. The numerical methods are described for correct representation of various thermal–physical phenomena such as flame propagation, turbulent mixing and flow acceleration. The principal advantages and shortcomings of various models are discussed.