Abstract
Numerical simulation of plasma spraying processes from the injection of metallic particles to formation of the coating was conducted by integrating plasma thermofluid, and splat and coating formation models. The first model clarifies the electromagnetic thermofluid fields of a particle-laden plasma flow impinging onto the substrate, as well as the characteristics of the fine particles injected in the plasma flow. The second model clarifies the splat thickness and diameter of a particle using the melted particle impact velocity and temperature obtained by the first model. Furthermore, the optimal particle impact velocity and temperature were derived from the stable splat criterion given by the integrated model.
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