Modeling thermal spray coating processes: a powerful tool in design and optimization

Widespread adoption of thermal spray technology requires the ability to apply a variety of coating materials, suited to each new application. Understanding the dependence of the microstructure of spray coatings on operating conditions of the thermal spray system is of great practical interest. To obtain good quality coatings the spray parameters must be selected carefully, and due to the large variety in process parameters, much trial and error goes into optimizing the process for each specific coating and substrate combinations. In this paper a complete model of the High Velocity Oxy–Fuel (HVOF) spray coating process is presented, including modeling three distinct sub-processes: spray parameters such as particle size, temperature, velocity, and impact points; particle impact and splat formation; and the coating microstructure including formation of porosity.