ɌȿKA. COMMISSION OF MOTORIZATION AND ENERGETICS IN AGRICULTURE – 2013, Vol. 13, No.4, 82-91

Design concepts of gaseous detonation guns for

Yuriy Kharlamov1, Maksym Kharlamov2

1Volodymyr Dahl East Ukrainian National University, Molodizhny bl., 20ɚ, Lugansk, 91034, Ukraine, e-mail: [email protected] 2E.O. Paton Electric Welding Institute 11 Bozhenko St., Kiev, 03680, Ukraine, e-mail: [email protected] Received September 12.2013: accepted October 10.2013

S u m m a r y . Presented a structural analysis of gaseous processes have exposed that higher detonation guns for spraying powder coatings and the performance and lifetime coatings can be possible variants of their operational cycle. The basic principles for the design of high detonation-gas plants produced if the feedstock particles are for spraying powder coatings, including the concept of a accelerated to a high velocity and heated prior valveless devices, are formulated. to impact on the substrate to be coated [4, K e y w o r d s . Gaseous detonation, coating deposition, 13, 27]. operational cycle. Almost in parallel to plasma spraying, Union (now Praxair Surface INTRODUCTION Technologies, Inc., Indianapolis. IN) marketed the trademarked D-Gun producing premium In spite of competing processes coatings, especially metallic and ones, (chemical vapor deposition (CVD), physical which have long been the goal of all other vapor deposition (PVD), etc.) and certain coating processes, i.e., higher density, drawbacks, thermal spray process sales are improved corrosion barrier, higher hardness, increasing regularly (almost by 10% per year better resistance, higher bonding and since 1990 [6]). The growth will probably cohesive strength, almost no oxidation, thicker continue, because spraying techniques are coatings, and smoother as-sprayed surfaces. relatively harmless to the environment and the However, the detonation gun (D-Gun) process full potential of thermal spraying as an was available only as a service [12]. alternative to more conventional coating Historically, the two fundamental modes techniques (e.g., hard ) for of combustion, namely flame and detonation, processing "multimaterials" or for free forming have found a wide variety of applications in and repairs is still undiscovered. However, this human activities. It is a slow flame that has development could be enhanced with been extensively utilized in propulsion, power increased quality of coatings and process engineering, material science, and chemical reliability. It demands improved process technology, while detonations were used understanding and on-line control with a real basically for military purposes. As the time closed-loop control. Decades of research knowledge in detonation physics and and development in thermal spray (TS) chemistry is continuously advancing, one DESIGN CONCEPTS OF GASEOUS DETONATION GUNS FOR THERMAL SPRAYING 83 inevitably arrives at the time when this detonation-gas plants for spraying of powder knowledge is to be used for constructive coatings. purposes as well to help humanity at large. Detonation is a very attractive phenomenon from the viewpoint of the thermodynamic BASIC PRINCIPLES OF GASEOUS efficiency of chemical energy conversion into DETONATION GUNS thermal and kinetic energy. Once this The detonation-spraying technique is advantage of detonation is capitalized cyclic. In a D-Gun, detonation is initiated in a properly, considerable benefits are expected to tube that serves as the combustor. The be achieved in terms of fuel consumption, detonation wave rapidly traverses the chamber manufacturing and operational costs, pollutant resulting in a nearly constant-volume heat emissions, etc. [1, 3, 20]. addition process that produces a high pressure For a long time, D-Gun technology has in the combustor and provides the formation of been the reference standard in producing high velocity impulse flow, which used for metallic and cermet coatings. However, as it powder heating and acceleration. A typical was available only as a service, no research duty cycle of detonation-gas spraying of work was published on the process. With the coatings and its main parameters are shown in transformations that occurred in the former Fig. 1. USSR, Russian equipment and literature on To facilitate the description and analysis the subject became available in the mid 1990s of basic physicochemical phenomena involved [19]. in the working cycle, nine principal steps will Gas detonation can be used to generate be considered: (1) filling the detonation gun thrust in engines, to induce force or destruction barrel with a fresh charge of combustible gas actions on objects located both inside and mixture (GF), (2) powder doze feeding into outside the device, to heat and accelerate DC (barrel) (PF), (3) creation of condensed particles, to rapidly burn the fuel, “phlegmatizing gas plug” between ignition etc. [19]. point and gas mixer (GP), (4) ignition of gas The development of detonation spraying mixture (Ig), (5) DC purging of residual gases is accompanied by broadening its industrial (Pr), (6) deflagration to detonation transition use [16]: deposition of coatings on aircraft (DDT), (7) impulse burn-out of the fresh engines and parts, jigs and fixtures [2], charge (B), (8) interaction of the powder strengthening of cumulative punches [8, 9], particles with an impulse flow of combustion improvement of wear resistance of work items products and two phase outflow from barrel re-adjustable dies [15], creation of a new (AP), (9) interaction of the gas-powder stream metal-working tools [17], hardening of with the substrate and single layer coating abrasive wheels, balancing of rotor systems formation (CF). [18], improvement of resistance to abrasion In the most general case the gaseous [21], etc. detonation gun (GDG), as an auto-oscillatory There are many different D-Gun designs system, has a block diagram shown in Fig.1. [14,23,24,28]. Unfortunately, the available The oscillatory system can also be represented literature contains no reliable data on the as a sequence of systems of the GDG itself and reliability of these devices and the comparative of the environment receiving the powder being analysis of their structural characteristics. processed (the product being coated, cooling Compared to HVOF or plasma spray chamber, etc.). The behavior (state) of the processes, much work, some of which is in environment may affect parameters of the progress, is necessary to better understand the working cycle because of the effect of phenomena of the D-gun process [10, 11]. feedbacks on the controllers and actuators. The aim of this work is to develop the Growing pressure to improve the performance basic principles of structural analysis and of D-Guns, as of IC engines, has resulted in synthesis of structures of high efficiency development of improved control systems [5]. 84 YURIY KHARLAMOV, MAKSYM KHARLAMOV

Fig. 1. A typical duty cycle of detonation-gas spraying and its main parameters

Fig. 2. Block diagram of gaseous detonation gun for thermal spraying DESIGN CONCEPTS OF GASEOUS DETONATION GUNS FOR THERMAL SPRAYING 85

The steps of an impulse burn-out of the the barrel first drops below atmospheric combustible mixture and formation of an pressure (because of the inertia of the flow) impulse heterogeneous stream are governing and then equalizes. The combustion chamber steps and depend greatly on the quality of is again filled with a fresh charge, and the barrel filling. Repetition of cycles causes the process is repeated. Thus, vibration burning fresh charge to contain a certain amount of with discontinuous oscillations (relaxation or combustion products and powder from the non-resonance burning) occurs in the barrel. preceding spraying cycle. The gases and The regularities in the burn-out of the powder, on the one hand, reduce the mass of a combustible mixture and in the outflow of fresh charge and, on the other hand, adversely combustion products from the barrel are the affect the processes of burn-out and formation scientific fundamentals to be considered in an of an impulse heterogeneous stream efficient development of spray-coating themselves. It is therefore natural to attempt to production processes [26]. However, this step reduce the fraction of residual gases and of the working cycle has not yet been studied powder in a fresh charge. Also the flow of a sufficiently. The most urgent issues for further working medium (purging gas, fresh investigations should include the following: combustible mixture or gas suspension of the the effect of design characteristics and the initial powder) has a limited time to overcome geometric configuration of the barrel, ignition the resistance of inlet paths, to contact heated chamber and other pre-barrel spaces on the surfaces etc. All this changes the density of the development and conditions of the working medium and hence also the mass of combustible mixture burn-out, outflow of charge capable of filling a barrel of detonation products and heat exchange with predetermined dimensions, the degree of barrel the barrel walls, the composition and filling, the spatial distribution of fresh charge properties of combustion products and their components in the barrel. The barrel-filling change during mixture burn-out and gas processes have been poorly studied. outflow from the barrel, the optimization of After the barrel has been filled, an the design characteristics of detonation- ignition source operates, installed in the spraying plants to provide the most efficient combustion chamber, or in an ignition conditions of combustible mixture burn-out chamber or in the combustible mixture feed and subsequent interaction of combustion piping. The mixture ignites, a flame front products with the powder. emerges, and burn-out of the combustible mixture occurs accompanied by progressive acceleration of the flame until a stationary OPERATIONAL CYCLE OF GASEOUS detonation mode arises. The flow field around DETONATION GUNS spark plug impacts the spark discharge in A specific feature of operation of spark ignited D-Guns. Ignition resulting from gaseous detonation gun (GDG) consists in spark discharge between spark plug electrodes periodical sustained oscillations of the is a crucial factor which strongly influences pressure, velocity, temperature, and accelerati- the combustion process [22]. As a on, which arise inside the barrel and other consequence the flow field around the spark structural elements of the GDG. The plug significantly affects D-Gun work oscillations are not caused by external repeatability and toxic components periodical effects and therefore belong to auto- concentration in exhaust gases. oscillations. Like any auto-oscillatory system, The pressure in the barrel during the GDG consists of the following main combustion rises and burn-out and is elements: energy source (a container or line accompanied by ejection of incandescent with a gaseous or liquid energy carrier and combustion products jointly with suspended oxidant), oscillatory system of a varying powder particles through the open end of the complexity (including the combustion barrel [25]. After the discharge, the pressure in chamber and control unit) with a definite 86 YURIY KHARLAMOV, MAKSYM KHARLAMOV dynamic characteristic, device controlling the The traditional structure of the operating energy input from the source into the cycle of the GDG (version 1) can be oscillatory system in both the amount and the represented as a sequential method of rate (the metered amount of energy defines the performing its individual steps: work accomplished by the GDG per a working cycle, while the rate, along with other system GFooooo PF GP Ig Pr parameters, defines the frequency or cyclicity . (1) of GDG operation, the cycle energy and the oDDT ooo B AP CF GDG operation frequency will define its power). A feedback providing the control of Elements GF, PF, GP, Ig and Pr belong the energy input (amount and rate) from the to the so-called preparatory ones, and elements source into the oscillatory-system exists DDT, B, AP, and CF to independent ones between this system and the control device [7]. which do not depend on the GDG control sys- Because of a specific nature of the production tem. Functions of elements GF, PF, and Ig are processes accomplished, the GDG are also clear from the essence of the DCP as an auto- fitted with a source of the powder material oscillatory system, while element GP is aimed processed (powder feeder), a device at providing a localization of the burn-out of controlling the powder feed into the com- combustible mixture in the combustion bustion chamber in the amount, rate, and time chamber and preventing flashbacks into the (the metered amount of powder will define the GDG actuators and energy source. output and the useful work performed by the Independent elements DDT, B, AP, and CF of GDG per a working cycle, the feed rate and the working cycle are separated for time interval, the spatial arrangement of convenience of the analysis and organization powder in a fresh charge and the nature of its of the control of processes proceeding at a interaction with combustion products), a pulsed burn-out of the combustible mixture. combustible mixture igniter, compressed gas Varying the parameters of the sources for the powder feed and combustion preparatory elements of the working cycle and chamber purging (cleaning), a feedback exists the design features of the GDG, predominantly between the oscillatory system and the powder of the combustion chamber, provides a means feed controller, the igniter (it provides for for controlling the independent (self- controlling the time between the combustion proceeding) elements of the working cycle and chamber filling and the combustible mixture thereby, e.g., the coating formation processes. ignition) and the purging gas controller, The operating frequency of a given GDG (provides for the control of the amount and is f 1/tc , where tc – operation cycle duration, rate of purging gas feed into the combustion ik tt chamber). ci1 ¦ , is composed of characteristic time i 1 The conditions of processing powder intervals of steps of operation cycle. For this materials are governed by the thermal, case i = 9. The gas and powder filling and velocity, and chemical relaxation of particles exhaust/purging processes tend to be the in a high-temperature two-phase pulsed stream longest duration. generated at every working cycle of the GDG. A version 2 represents a common The relaxation of particles is conditioned by combination in time of the processes of filling the parameters of the entire system under the combustion chamber with a fresh mixture consideration and depends not only on the and feeding the powder: energy of a single pulse and the parameters of the high-temperature gaseous medium, but GF also on the spatial arrangement of a fresh gas ooooGP Ig Pr . (2) charge and a single dose (metered amount) of PF oDDT ooo B AP CF powder. DESIGN CONCEPTS OF GASEOUS DETONATION GUNS FOR THERMAL SPRAYING 87

In this case operation cycle duration will products before filling of the combustion be ttttc2134 ... t 9, that is will be shorter as chamber: a result of combining of gas and powder GF filling. oooIgPr DDT ooo B AP CF . (6) We will now consider the specific PF features of other versions of the GDG working cycle structure. Version 7. Differs from the preceding Version 3. When powder feed actuators one in that the powder feed is carried out are present, a command from the control similarly to version 3: system arrives after the delivery (or even execution) of the command for initiating the GFoo Ig PF combustion: p . (7) Pr oDDT ooo B AP CF GFooo GP Ig PF p . (3) Version 8. Differs from version 6 by a Pr oDDT ooo B AP CF sequential filling of the combustion chamber with a fresh mixture and in the powder feed In this case for given GDG operation method: cycle duration ttcc23 . However, the time of operation of the pulse feeder of powder should GF PF Ig Pr oooo . (8) be matched with the flame propagation time oDDT ooo B AP CF and with the period of its pre-detonation acceleration. In view of a considerable lag of Versions 9 and 10 are combinations of powder feed devices, ignition and combustion the specific features of structure 4 and 6, 5 and chambers should be connected by passages 6 respectively: providing for a delay of combustible mixture ignition in the barrel, sufficient for introducing GF o Ig o Pr o DDToo B AP o CF the powder. Another way consists in using a p . (9) direct combustion process for the powder feed. PF Version 4. The powder feed is effected by the gaseous mixture combustion products in GFoIg o Pr o DDT ooo B AP CF the detonation mode: p . (10) PF Ig o DDToo B AP o CF GFoo GP Pr o . (4) p Subsequent versions are derivatives from PF preceding ones and differ by a restriction of the combustible mixture burn-out by the pre- Version 5. Differs from the preceding detonation mode: 11 corresponds to 1, 12, to 2, one by the use of burnout products in the pre- 13, to 3, 14, to 5, 15, to 6, 16, to 7, 17, to 8: detonation mode:

GFooooo PF GP Ig Pr GFoo GPIg o Pr o DDT ooo B AP CF . (11) p . (5) ooB AP o CF PF GF ooooooGP IgPr B AP CF . (12) Version 6. Elimination of the combustion PF chamber "locking" is attained by means of special design features of the GDG, with the GFooo GP Ig PF aid of hard-to-ignite combustible gases and at p . (13) Pr ooB AP o CF a relatively low frequency of GDG operation, which ensures cooling of the combustion 88 YURIY KHARLAMOV, MAKSYM KHARLAMOV

GFoo GPIg o Pr o B oo AP CF ignition and combustion chambers, properties p . (14) of the combustible mixture, and parameters of PF filling with a fresh combustible mixture and powder. Only a partial automation of the GDG GF control, associated with the execution of the oooooIgPr BAPCF. (15) PF working cycle, has been attained at present. The operator, however, has to interfere all the time with the GDG operation control at its GFoIg o Pr o B oo APCF p . (16) starting (sequential feed of individual working PF gases and powder, switching-on of the ignition and actuation of protective devices to protect the surface to be sprayed until the plant GFoooooo PF IgPr B AP CF . (17) reaches the working conditions, gaining of the working conditions by the plant, feed of the Purging for removing residual gases is part being coated, monitoring the spraying not considered since it is in fact combined with process on instruments and visually) as well as filling the combustion chamber with the with the spraying process when intolerable combustible mixture. deviations from the parameters occur. The The above-described features of the production process quality therefore depends working cycle can be implemented in more to a great extent on the operator's skill. numerous design versions of the GDG, but the working cycle of any of them consists of the above-considered elements. Their analysis will D-GUN DESIGN CONCEPTS make it possible to create a scientific basis for calculating and designing the processes The permanent efforts are directed to the proceeding in the GDG. Comparing and achievement of the highest quality of coatings evaluating different versions of the working and productivity of GDS at lowest possible cycle structure are possible only at a joint cost. This may be achieved: analysis of their design features and physical Firstly: by better understanding of principles of GDG operation. patterns of relationship of DGS operation The sequence of accomplishing cycle, by better understanding of gaseous individual elements of the working cycle is detonation products interaction with processed given by the GDG operation cyclogram. The powder, by search of methods for powder plants are of two types: with an adjustable particles behavior control at impulse jet, by (changes can be made, when required, in the better understanding of impulse jet-substrate cycle duration and operation of its individual and particle-substrate interaction, elements as well as in the time intervals Secondly: by continuous improvement of between them) and non-adjustable (rigid) process technology of DGS on basis of system cyclogram of the working cycle. The former approach and better understanding of materials type of cyclograms is typical for general- interaction in process of coating formation, by purpose GDG intended for depositing coatings full control of all parameters involved in the of various types and on various products GDS, by adequate GDS process simulation (having different service functions, shapes, and optimization of all working conditions, sizes, arrangement of surfaces being coated). Thirdly: by development of the fully The latter type of cyclograms, which makes adaptive systems for GDS and the process possible the use of simpler and more reliable monitoring devices. control systems, is more preferable for special In order to use propagating detonations and specialized GDG. for processing of powder materials and realize The regularities of implementing the the D-guns advantages, a number of independent elements of the working cycle are challenging fundamental and engineering primarily determined by the design features of problems has yet to be solved. These problems DESIGN CONCEPTS OF GASEOUS DETONATION GUNS FOR THERMAL SPRAYING 89 deal basically with low cost achievement and oxidant, 2. typical mode of gas mixture control of successive detonations in a gaseous burning, 3. type and design philosophy of detonation device. To ensure rapid barrel (configurations of transverse and development of a detonation wave within a longitudinal sections, microgeometry of barrel short cycle time, one needs to apply (1) surface, type of cooling, attitude position), 4. efficient fuel injection and oxidizer supply type, location and operation mode of ignition systems to provide fast and nearly generator, 5. technique of predetonation homogeneous mixing of the components in the distance control, 6. peculiarities of gaseous detonation chamber (DC), (2) efficient powder exchange at barrel, 7. technique for gas injection and supply systems to provide mixture preparation and flow rate control, 8. mixing of powder with gas mixture and initial gas mixture pressure at barrel, 9. controllable location into DC, (3) low energy technique for localization of gas mixture source for detonation initiation to provide fast burning at barrel, 10. technique and point of and reliable detonation onset [20], (4) cooling powder injection into barrel, 11. ambient technique for rapid, preferably recuperative, medium of spraying, and others. heat removal from the walls of detonation Valved D-Gun concept implies the use chamber (DC) to ensure stable operation and of mechanical or electromagnetic valves to avoid premature ignition of gaseous mixture ensure a controlled (periodic) inward flow rate leading to detonation failure, (5) geometry of of fuel-oxidizer mixture into the DC, to the combustion chamber to promote prevent detonations or shocks from moving detonation initiation and propagation at lowest outwards from the DC through the inlet, and to possible pressure loss and to ensure high provide a sufficient time for mixing of fuel operation frequency and control of powder with air. Several designs with mechanical or heating and acceleration, and (6) control electromagnetic valves are available in methodology that allows for adaptive, active literature. These types of D-Guns are in control of the operation process to ensure industrial use. optimal performance at variable processing Valveles D-Guns concepts imply conditions, while maintaining margin of continuous or intermittent supply of stability of repetitive two phase impulse jets. propellants (fuel and oxidizer) to the DC In addition to the fundamental issues dealing without using mechanical valves. with the processes in the DC, there are other Predetonator concept implies the use of issues such as (7) efficient integration of DC a two-step detonation initiation process in the with inlets and nozzles to provide high DC, namely, the use of an additional, highly performance. The other problem is noise. sensitive reactive mixture contained in a tube Therefore, the equipment for detonation-gas of small diameter and readily detonated by a spraying should be placed in soundproof source of low energy, and transmitting the booths. It is promising additional reduction of obtained detonation wave into the larger- noise by suppressing the noise themselves diameter DC containing considerably less detonation-gas guns, including the use of sensitive reactive mixture. The small-diameter devices for active noise reduction. tube is referred to as predetonator. To date it are created manifold gaseous Enchanced deflagration to detonation detonation guns (DG) which differ by mode of transition (DDT) concept implies the use of functioning (principle of operation) and various passive means to promote DDT and embodiment. Therefore it is urgent question of obtain a detonation wave in the main DC with estimation of technological capabilities, as the working mixture ignited by a low-energy advantages and shortages of different variants source. of DG and development of justified Stratified-charge concept implies recommendations for their industrial controlled injection of propellants into the D- application. For DG classification the next Gun DC aimed at formation of the explosive attributes are used: 1. types of fuel and charge with variable spatial sensitivity to 90 YURIY KHARLAMOV, MAKSYM KHARLAMOV detonation. Stratified explosive charge can be REFERENCES obtained by proper timing of fuel and/or oxidizer valves, by controlled distributed 1. Bazhenova T. V., Golub V. V., 2003.: Use of Gas Detonation in a Controlled Frequency Mode injection of fuel and/or oxidizer along the DC, (Review), Combustion, Explosion, and Shock or by various geometrical means creating a Waves, Vol. 39, No.4, 365-381. 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