Full-Scale Numerical Simulation of Plasma-Sprayed Functionally Gradient Materials

Abstract

To develop novel and advanced thermal barrier coatings, full-scale numerical simulation of plasma-sprayed functionally gradient materials is conducted in this paper, including the prediction of basic parameters at the nozzle exit, simulation of three dimensional simulation of the plasma jet, modeling of the interaction between the plasma jet and the particles, calculation of flight trajectories and temperature history of flying metal and ceramic particles, the interaction between the molten particles and the substrate, as well as the deposition process of the coatings. Various complex phenomena, such as turbulent effects with chemical reactions in the plasma jet, dispersion status of the particles onto the substrate, and the composition distribution of the functionally gradient materials, are fully taken into account. The numerical simulation results are found to be in good agreement with experimental evidence.

A Review of the Developments of the Characteristics and Mechanisms of Airless Spraying on Complex Surfaces

“…The spraying methods include air spraying [8][9][10], electrostatic spraying [11,12], plasma spraying [13][14][15], high-pressure airless spraying [16,17], etc. Airless spraying, owing to its unique spraying principle, always features excellent film quality, spraying efficiency, coating adhesion and environmental friendliness, and it is capable of achieving high-viscosity, high solid component and thick-coat spraying.…”