Full-scale modelling of a thermal spray process

An attempt at the comprehensive simulation of a thermal spray process is made. The simulation tool consists of physical models and their computational realisations for major elements of the process such as: plasma torch; particle motion and heating; plasma-substrate and particle-substrate interaction; and formation of the deposited layer. Simulation results are compared with experimental data for LPPS. Using a simplified thermo-mechanical splat model and statistical model of particle deposition, some aspects of microstructure formation are studied. Influence of particle size, temperature and speeds, as well as spray angle and stand-off distance, on the coating structure and surface texture is investigated. Influence of the motion control and process parameters on the coating porosity and microstructure is discussed. Examples of sensitivity analysis and coating optimisation for those parameters are presented.