Unsteady heat transfer problem during single-pass spraying on a half-space

Objectives. Thermal spraying and powder laser cladding are promising technologies widely used in various industries, including aerospace, energy, and mechanical engineering. The efficiency of these technologies depends on the management of thermal processes occurring during coating application, which directly affect the quality and durability of the resulting materials and products. This article considers a nonstationary problem of heat transfer during single-pass spraying on a half-space. The research aim was to simulate the temperature distribution in a material half-space upon the action of a moving heat source on its boundary.

Methods. A theoretical study of the temperature distribution on the surface and in the bulk of the processed material during movement of the spray head was carried out by solving the equation of nonstationary thermal conductivity in Cartesian coordinates. This equation employs a special type of the heat source power density function in the form of a thermal strip, simulating the process of heat transfer from the spray path to the material half-space of the part base.

Results. The obtained solution representing the evolution of temperature in time at different points of the medium shows that at a certain point of time after the passage of the heating pulse, the temperature inside the medium reaches its maximum value rapidly followed by its relatively slow relaxation to the equilibrium temperature of the environment. Penetrating deeper into the bulk of the medium, the thermal pulse is spreading out while decreasing its amplitude and increasing its width, accompanied by a monotonic increase in the time to reach the maximum. The transverse temperature distribution has the form of symmetrical peaks, less pronounced in depth.

Conclusions. The obtained solution can be used when describing the general temperature field at some distance from the spray head area, where specific heating details are lacking. In particular, the work shows that significant temperature gradients arise in the vicinity of the primary spray area, which will cause noticeable nonstationary temperature stresses. 

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