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SpaceX
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NASA
СпутникиРНSpaceXРоскосмосNASATo address challenges in thermal barrier coating (TBC) applications for confined spaces and non-circular cross-sections, this study develops an integrated high-quality spraying process for flame tubes and gas ducts, providing an innovative technical solution for advanced aero-engine development. A novel high-velocity oxygen-fuel (HVOF) spraying system is proposed. First, computational fluid dynamics (CFD) simulations validate the design rationality and optimize critical parameters. Subsequently, CoNiCrAlY bond coats for TBCs are deposited on representative components. Systematic analyses of unmelted particle content, porosity, and oxidation levels in coatings produced by the new spray gun confirm process reliability. The results demonstrate that this optimized system achieves uniform coating deposition in complex geometries while maintaining low porosity (
To address challenges in thermal barrier coating (TBC) applications for confined spaces and non-circular cross-sections, this study develops an integrated high-quality spraying process for flame tubes and gas ducts, providing an innovative technical solution for advanced aero-engine development. A novel high-velocity oxygen-fuel (HVOF) spraying system is proposed. First, computational fluid dynamics (CFD) simulations validate the design rationality and optimize critical parameters. Subsequently, CoNiCrAlY bond coats for TBCs are deposited on representative components. Systematic analyses of unmelted particle content, porosity, and oxidation levels in coatings produced by the new spray gun confirm process reliability. The results demonstrate that this optimized system achieves uniform coating deposition in complex geometries while maintaining low porosity (< 0.2%) and minimal oxidation (0.3% oxide content), fulfilling stringent requirements for high-temperature protective coatings in next-generation engines.
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This research was funded by “Insight Action” Achievement Transformation and Application Project (Program No. 0399tbJC36024100001).
School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, China
Zelin Song, Shilin Xu & Chaorun Si
Kapabol Surface Technology Co. Ltd., Wuxi, 214203, China
Shilin Xu, Song Chen, Zhen Rong, Jianren Huo, Gengwang Cao, Lei Xu & Erbin Feng
AVIC Shenyang Engine Design and Research Institute, Aero Engine Corporation, Shenyang, 110066, China
Hongyu Ma, Baohua Zhang & Yi Zhang
Authors
Correspondence to Chaorun Si.
School of Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang, China
Jianrong Tan
School of Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang, China
Zhenyu Liu
Mechanical Engineering, Zhejiang University, Hangzhou, Zhejiang, China
Weifei Hu
© 2027 The Chinese Mechanical Engineering Society
Song, Z. et al. (2027). Design of a New HVOF Spraying Gun and Its Application in Preparation of CoNiCrAlY Bond Coat for Thermal Barrier Coatings. In: Tan, J., Liu, Z., Hu, W. (eds) Advances in Mechanical Design. ICMD 2025. Mechanisms and Machine Science, vol 206. Springer, Singapore. https://doi.org/10.1007/978-981-95-7904-4_31
Download citationDOI: https://doi.org/10.1007/978-981-95-7904-4_31
Published: 25 June 2026
Publisher Name: Springer, Singapore
Print ISBN: 978-981-95-7903-7
Online ISBN: 978-981-95-7904-4
eBook Packages: Mechanical Engineering (R0)Springer Nature Proceedings excluding Computer Science