TITLE:
Efficient Simulation of Nonlinear Heat Transfer during Thermal Spraying of Complex Workpieces
AUTHORS:
Rolf Berthelsen, Thomas Wiederkehr, Ralf Denzer, Andreas Menzel, Heinrich Müller
KEYWORDS:
Nonlinear Heat Conduction, Continuum Thermodynamics, GPU Computing
JOURNAL NAME:
World Journal of Mechanics,
Vol.4 No.9,
September
29,
2014
ABSTRACT: The quality of coatings, produced by thermal spraying processes,
considerably decreases with the occurrence of higher residual stresses, which
are especially pronounced for complex workpiece geometries. To understand the
occurring effects and to aid in the planning of coating processes, simulations
of the highly transient energy flux of the HVOF spray gun into the substrate
are of great value. In this article, a software framework for the simulation of
nonlinear heat transfer during (HVOF) thermal spraying is presented. One part
of this framework employs an efficient GPU-based simulation algorithm to
compute the time-dependent input boundary conditions for a spray gun that moves
along a complex workpiece of arbitrary shape. The other part employs a
finite-element model for a rigid heat conductor adhering to the computed
boundary conditions. The model is derived from the fundamental equations of
continuum thermodynamics where nonlinear temperature-depending heat conduction
is assumed.