Session BB1.3

9:15 AM BB1.3
USING DIAGNOSTIC AND MODELING TOOLS TO OPTIMIZE THE HVOF PROCESS. Richard A. Neiser, Mark F. Smith, Sandia National Laboratories, Materials and Process Sciences Center, Albuquerque, NM.

Non-invasive diagnostic techniques combined with numerical and analytical models greatly enhance our understanding of thermal spray processes. These tools provide an excellent means for improving the robustness of the process and the quality of the sprayed deposits. This paper will present results generated during a cooperative research and development agreement (CRADA) between Sandia National Labs and General Motors that studied a High-Velocity Oxy-Fuel (HVOF) process for depositing wear resistant cylinder bore coatings in aluminum automobile engines. The paper will discuss how particle diagnostic tools and statistical and analytical models were used to characterize and optimize the process. Wire melting, droplet atomization and acceleration, particle heating in-flight, and the influence of processing parameters on particle size, temperature, and velocity will be discussed.