Abstract
Substrate heating in the plasma spray process is one of the important parameters, which affects the microstructure of coatings and bonding between coating and substrate. In this study, a three-dimensional numerical model is developed to study the thermal exchange between the plasma jet and the substrate. The plasma jet temperature and velocity distributions and thermal flux to the substrate surface are predicted. The effects of arc current, gas flow rate, and stand-off distance on the temperature and velocity fields of the impinging plasma jet and thermal flux to the substrate are clarified. Results indicate that the three-dimensional effect has a very weak influence on the substrate heating. The air entrainment is compared for different cases. The present model is validated by comparing the present results with previous predictions and measurements. The temperature distributions in the substrate for different stand-off distances are predicted.
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