Abstract
A warm spray system has been computationally investigated by introducing a centrally located mixing chamber into a HVOF thermal spray gun. The effects of injecting a cooling gas on the gas and particle dynamics are examined. The gas phase model incorporates liquid fuel droplets which heat, evaporate and then exothermically combust with oxygen within the combustion chamber producing a realistic compressible, supersonic and turbulent jet. The titanium powder is tracked using the Lagrangian approach including particle heating, melting and solidification. The results present an insight into the complex interrelations between the gas and particle phases, and highlight the advantage of warm spray, especially for the deposition of oxygen sensitive materials such as titanium. This work also demonstrates the effectiveness of a computational approach in aiding the development of thermal spray devices.