Abstract
For the simulation of thermal spray coating build-up and the prediction of the coating-thickness distribution on given workpieces, an accurate representation of the mass flow emitted from the spray torch is essential. For two-dimensional (2D) simulations, this flow function often is acquired by measuring the coating thickness in cross-sectional profiles of linear spray beads, and for 3D simulations, usually some form of rotationally symmetric normal distribution function is fitted to measured profile data. However, when using free-formed complex workpieces or arbitrary and nonuniform spray paths, more realistic, nonsymmetric, and 3D flow functions are required. We present an approach to acquire accurate and fully 3D flow distribution functions by measuring 3D coating profiles which result from spraying onto a flat surface with a stationary gun, and improving them by means of a developed optimization method that takes more precise cross-sectional measurements into account. This approach thus combines the advantages of the higher accuracy of 2D measurements while fully preserving the 3D characteristics of the measured profile.
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