Interaction of solid particles with shock and expansions in supersonic flows is analyzed. In this analysis, a dense cloud of solid particulates is modeled by using a fully Eulerian approach. The dispersed flow and the gas flow were considered in the Eulerian frame whereby most of the physical aspects of the gas-particle flow can be incorporated. In addition to the momentum and energy exchanges in the form of source terms appearing in the governing equations, the two phases were strongly coupled by considering the volume fraction of the particulate phase in the equations. The simulation performed for a High Velocity Oxy-Fuel (HVOF) process under typical operating conditions in which the powder loading is high and the two-phase flow is not dilute near the injection port. The simulations showed large variations in the flow regime in the region that most of the particles exist. Unlike the results corresponding to the Lagrangian approach, the flow becomes subsonic near the centerline and the drag force decreases significantly since the relative Mach number is small. The validation experiments showed that the variation of flow regime by changing the relative Mach number could significantly change the particle drag force, and consequently process efficiency.

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