In this work, a CFD model is built to investigate gas flow and in-flight particle characteristics in HVOF spraying with hydrogen as the fuel. Gas flow is solved for a particle-free jet, combustion is represented using a simple eddy-dissipation model, and a time-averaged fluid flow (k-ε) model is used to account for turbulence. Acceleration and heating of individual particles are modeled in a "snapshot" of the gas flow. Particle acceleration is shown to be governed by drag and particle heating by conduction and radiation between particulates and gas phases. Modeling results agree well with experimentally obtained data and observations.

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