Varying Process Parameters Research Articles

Colloidal state-based studies on the chloride salts of magnesium- and calcium-induced coagulation of soymilks.

Chloride salts (MgCl2 and occasionally CaCl2) coagulation of the heated soymilks is the key step in manufacturing traditional tofu. In this study, colloidal state diagrams were constructed first, and then the effects of processing parameters, including coagulant concentration, preheating intensity, protein concentration, and coagulation temperature as well as the intrinsic properties (phytate concentration) on the microstructure, protein coagulability, and water holding capacity (WHC) were investigated to gain an overall framework understanding of the Mg2+ and Ca2+ coagulated soymilk process. As the variables changed, the coagulated soymilks displayed one of the following states: colloidal suspension, flocs, weak gel, and strong gel. The microstructures of the coagulated systems also changed to different features with the variation in processing parameters and phytate concentrations. Several interesting results were obtained. It was found that the transformations from colloidal suspension to gel state were usually corresponding to the increase of particle size, the decrease of porosity, and a sharp increase in protein coagulability. The colloidal states of Mg2+ and Ca2+ coagulated soymilks were usually different, but their microstructures were similar. With the increase of protein concentration, the protein coagulability decreased but the WHC was enhanced. The presence of high phytate contents led to form small protein agglomerates, which resulted in worse protein coagulation and WHC. It is expected that this study will deepen the understanding of chloride salts coagulation process.

Characterization of Direct Ink Writing carbon fiber composite structures with serial sectioning and DREAM.3D

Direct Ink Writing (DIW) combines the flexibility of 3D printing with increased material applications such as thermoset carbon fiber composites, ceramic composites, and metals. The usefulness of direct ink writing, like many additive manufacturing (AM) processes, remains limited for reasons ranging from quality control to lack of process parameter optimization. This study looks to introduce a methodology for characterizing direct ink written carbon fiber composites to facilitate exploration into the relationships between process parameters and material structure. The presented study utilized nine 3D specimens of direct ink writing carbon fiber composites printed with varying process parameters – speed differential, layer height, step-over distance, and nozzle diameter – as the data set. The data was collected with an automatic serial sectioning system, LEROY, from the Air Force Research Laboratory. The collected data was processed in DREAM.3D and analyzed with statistical comparisons of 2D orientation distributions of the fibers, 2D size distributions of the voids, and 2D shape distributions of the voids.

Nanosecond laser ablation of micro-pits in Ni60/WC coatings with coupled thermal-stress simulation and parameter optimization

In order to solve the problem of crack sprouting inside the micro-pit caused by improper design of laser ablation process parameters, this study establishes a thermal-stress coupling simulation model of nanosecond laser ablation of micro-pits on Ni60/WC coated surfaces. It researches the influence of laser process parameters (laser power, scanning speed, processing times) on the index parameters of micro-pit diameter, depth, and maximum residual stress. The weighting of diameter, depth and maximum residual stress sub-objectives in the comprehensive evaluation objectives of micro-pits are calculated. The response surface method of Central Composite Design (CCD) and regression analysis are used to fit the response surface functions of micro-pit diameter, depth, and maximum residual stress as a function of the variation of laser ablation process parameters. The Genetic Algorithm (GA) is used to minimize value of the maximum residual stress sub-objective function and to optimize the process parameters of laser ablation of micro-pits, using the values interval of the micro-pit diameter and depth functions as nonlinear constraints. The results show that the maximum residual stress varies quadratically with laser power and scanning speed, increases linearly with the processing times, and is coupled with the ablation process parameters. A design method for optimizing the parameters of nanosecond laser ablation by maximum residual stress is established, and the process parameters are optimized to meet the design parameters and quality requirements of micro-pits: laser power of 12 W, scanning speed of 276 mm/s, and 4 times of processing. The optimized process is provided for the parameter tuning nanosecond laser ablation of micro-pits on Ni60/WC coating surfaces.

The Influence of Process Parameters on Tensile Features of Vetiver Fiber Reinforced Polymer Matrix Composites

Due to their outstanding specific strength and modulus, fiber-reinforced polymer composites have long been influential in a range of applications. Composites made of thermoplastic and vetiver fiber (VF) offer an alternative to synthetic polymers that cause environmental contamination. The advantages of natural fibers (like banana, sisal, coir, jute, vetiver, flax, hemp, kenaf, etc.) over conventional reinforcing fibers (glass and carbon fiber) are their ease of procurement, renewability, non-corrosive nature, light density, biodegradability, high specific energy (strength of density ratio), and low cost. In place of costly chemical treatment of VF in polymer composites, VF length management has been offered as a low-cost and ecologically friendly alternative. In the current study, VF-reinforced low-density polyethylene (LDPE) composites were altered using the film process stacking method with the hot press compression molding technique using a variety of process parameters, including VF condition (untreated and sodium dodecyl sulfate (SDS) treatment), VF sizes (short VF < 3 cm and long VF > 3 cm), and VF percent (5, 10, and 15 wt%). The tensile modulus and modulus efficiency factor of the LDPE composite were studied in relation to the impacts of VF size, VF content, and SDS treatment. The results showed that a specific amount of tensile modulus and modulus efficiency factor was boosted by VF content up to 10 wt%, processing temperature up to 160oC, and SDS treatment during processing up to 5 hours due to an increase in load bearing and interfacial adhesion. The improvement in tensile modulus and its efficiency factor because of efficient load transfer is evidently attributable to long VF load transfers, which have had a favourable impact. The brittle nature of the fibers caused a loss in ductility.

Ultrasonic shot peening (USSP) post-treatment of Ni laser cladding on mild steel

The ultrasonic shot peening (USSP) technique serves as a reliable post-treatment method for various industrial components to prevent functional failures. This study aims to develop hybrid Ni claddings approximately 300 µm thick on mild steel using laser cladding (LC) and USSP techniques. Morphological studies reveal that the claddings exhibit enhanced closure of cracks, increased hardness, and improved scratch resistance after peening. XRD analysis confirms the presence of compressive residual stress, as well as grain refinement and texturing effects after the peening. Furthermore, the research endeavors to improve their mechanical and electrochemical properties by employing USSP's varied process parameters in a hybrid approach. After undergoing USSP treatment, the average surface roughness was increased by up to 6 µm due to the formation of dimples, while it was 8 µm in the as-cladded and only 1.5 µm after polishing. Furthermore, compared to the as-cladded and polished claddings, the hybrid claddings exhibit a hydrophobic character linked to improved corrosion resistance and better in-depth roughness profiles.

Improving wear resistance of Ti6Al6V2Sn alloy by reinforcing AlBeSiTiV high-entropy alloy through microwave sintering

The present study examines the wear performance of microwave-sintered Ti6Al6V2Sn (Ti662) alloy reinforced with 15 wt% AlBeSiTiV High-Entropy Alloy (HEA). The AlBeSiTiV HEA is synthesized by ball milling at 250 rpm for 20 h, resulting in irregular fragments with a mean size of 15 µm and an FCC phase structure. The α-Ti grains decreased with increment of β -Ti grains upon adding HEA reinforcement with the Ti662 alloy. The Ti662/HEA composite exhibited 762 HV microhardness mainly due to refined grains through uniform dissipation in the sintering. The grains sized 0.597 µm on average. The pin-on-disc tribometer is employed to evaluate the wear rate of Ti662/HEA composite under varied process parameters such as applied load, sliding velocity, and sliding distance resulted in enhanced wear resistance through grain refinement, hindering effect, and superior interfacial bonding properties of reinforced HEA particles. Morphological analysis of the worn surfaces reveals wear mechanisms, including delamination, grooves, and the formation of oxide layers. These layers are developed due to the reinforcement of HEA with Ti662 alloy, serving as a protective film over the composite surface against wear.

Experimental Study on Preparation of Nano ZnO by Hydrodynamic Cavitation-Enhanced Carbonization Method and Response Surface Optimization

The carbonization method for preparing Nano ZnO is characterized by its simplicity, ease of reaction control, high product purity, environmental friendliness, and potential for CO2 recycling. However, traditional carbonization processes suffer from poor heat and mass transfer, leading to in situ growth and agglomeration, resulting in low carbonization efficiency, small specific surface area, and inferior product performance. To enhance micro-mixing and mass transfer efficiency, ZnO derived from zinc ash calcination was used as the raw material, and hydrodynamic cavitation technology was employed to intensify the carbonization reaction process. The reaction mechanism of hydrodynamic cavitation was analyzed, and a single-factor experimental study investigated the effects of reaction time, reaction temperature, solid–liquid ratio, calcination temperature, incident angle, cavitation number, and position height on the specific surface area and carbonization rate of Nano ZnO. The response surface method was utilized to explore the significance of the three most influential factors—solid–liquid ratio, cavitation number, and position height—on the carbonization rate and specific surface area. The products were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), laser particle size analysis, and specific surface area analysis. The results showed that the optimal process parameters were a reaction temperature of 80 °C, a reaction time of 120 min, a solid–liquid ratio of 5.011:100, a calcination temperature of 500 °C for 1 h, an incident angle of 60°, a cavitation number of 0.366, and a position height of 301.128 mm. The interaction between solid–liquid ratio and position height significantly influenced the process parameter variations. Under these conditions, the specific surface area and carbonization rate were 63.190 m2/g and 94.623%, respectively. The carbonized product was flaky Nano ZnO with good dispersion and small particle size. Compared to traditional mechanical stirring and bubbling methods, the specific surface area increased by 1.5 times, the carbonization rate improved by 10%, and the particle size decreased by half, significantly enhancing the product performance.

Identification of Cause–Effect Relationships between Process Parameters and the Film Formation in the Semidry Electrode Production for Lithium‐Ion Batteries

Conventional electrode production for lithium‐ion batteries has high energy and plant space demand, due to the high solvent content of the slurry to be processed by slot die or doctor blade coating. By using the semidry electrode production, the solvent content is reduced by more than 50% compared to the conventional electrode production, decreasing energy demand and drying length. Regarding technology readiness level, the semidry electrode production is on the pilot scale, as the basic principles have been shown. However, many unknown cause–effect correlations exist between the process parameters and the product properties. This study aims to analyze process parameter variations and their influence on the geometric, electrochemical, and mechanical properties of the electrode. An experimental design is utilized to obtain statistically relevant conclusions. It is found that the first calender gap and the roller speed influence the mass loading and the porosity of the electrode. The roller speed significantly influences the ionic resistance within the electrode, which may be attributed to the used release foil.

Removal of Cr(VI) from aqueous phase using dimethylaminopropylamine anchored polystyrene‐co‐divinylbenzene polymer as adsorbent

AbstractThe current investigation delves into the effectiveness of dimethylaminopropylamine tethered onto polystyrene‐co‐divinylbenzene polymer for the proficient elimination of hexavalent chromium from simulated wastewater. The resin was characterized using SEM, FT‐IR spectroscopy, EDX, elemental analysis, thermogravimetry, and solid state 13C NMR spectroscopy. The experimental investigation into sorption dynamics involved varying process parameters, including initial Cr(VI) concentration, amount of adsorbent used, solution pH, temperature, and contact between phases. The binding modes of chromate ions, either bidentate or monodentate, were observed, with their manifestation influenced by the solution's pH. Sorption capacity was found to be pH‐dependent, with removal efficiencies of 98.27%, 96.38%, and 85.52% observed at pH levels of 3, 6, and 9, respectively. PS‐DMAPA resin demonstrated robust regeneration capabilities, throughout five consecutive adsorption–desorption cycles. The Langmuir adsorption model exhibited excellent agreement with the experimental findings (R2 = 0.9994), revealing a maximum adsorption capacity of 70.15 mg g−1 at 298 K. Additionally, the experimental findings closely matched the second‐order kinetic model. The kinetics of sorption and the thermodynamic parameters were also investigated. Performance evaluating of the PS‐DMAPA resin under dynamic conditions included analyzing the Cr(VI) breakthrough curve. The 10% sodium chloride solution was employed to effectively recover the extracted Cr(VI) quantitatively.

Process Parameter Variation and its Impact on the Mechanical Characteristics of 3D-Printed Structures

Process Parameter Variation and its Impact on the Mechanical Characteristics of 3D-Printed Structures

Evaluation of a triethylenetetramine-chitosan derivative for the removal of palladium ion from an intricate adsorbate system

Palladium (Pd), a well-known noble metal for its exceptional physical and chemical properties, finds widespread applications in sectors including automotive, hydrogen purification, dentistry, coinage, and jewelry. The growing demand for Pd has led to resource scarcity. This feature necessitated upon the economically and environmentally viable means for the reclamation of the precious metal ions from secondary sources. This article delves into the Pd adsorptive-desorption trends associated with the triethylenetetramine cross-linked chitosan (CH-TETA) derivative in moderately complex solutions. The effect of moderate solution chemistry complexity, incorporating ammonium hydroxide (NH4OH) and ethylenediaminetetraacetic acid (EDTA), within the synthetic electroless plating (ELP) solutions was investigated. Batch adsorption experiments were conducted through a variation of process parameters namely solution pH, CH-TETA dosage, adsorption duration, initial Pd concentration, and temperature. CH-TETA demonstrates an impressive Pd adsorption capacity ranging from 43.53 to 117.08 mg g⁻¹ and is correspondingly accompanied by the metal removal efficiency range of 87.05 % to 39.03 %. Such promising performance has been ascertained for an initial Pd constitution of 50 to 300 mg L⁻¹. Despite constituting other additives in the adsorbate system, utilizing simple acidic and basic eluents, the CH-TETA derivative exhibited a reasonable recovery efficacy of 39.68 %. Thereafter, recovery of Pd can be further enhanced into two approaches. In these, the first refers to the utilization of various other methods such as thermal, electrochemical, ultrasound, and microwave-assisted regeneration from spent adsorbents. Secondly, a pre-treatment method can be adopted to remove the additives prior to the adsorption process. In summary, the recovery of precious metal ions from the spent adsorbents has been a challenging task. Based on the discussion, further improvements based on the findings of this article are possible by targeting relevant research methodologies in resin chemistry and regeneration methods.

Synthesis of strontium and manganese co-doped hydroxyapatite nanoparticles by ultrasound-supported hydrothermal technique and Taguchi design of experiments for biomedical applications

The present study aims to develop Strontium (Sr) and Manganese (Mn) co-doped Hydroxyapatite (HA) nanoparticles using the Taguchi design of experiments to understand the effect of process parameters on cell viability of human osteosarcoma MG-63 cells and antibacterial properties. An ultrasound-supported Hydrothermal technique was implemented for the synthesis, considering hydrothermal temperature; time for ultrasonic pretreatment; concentration of Sr; and concentration of Mn as important variable process parameters. They were varied at 145°C, 160°C, and 175°C; 10 min, 20 min, and 30 min; 0 wt%, 5 wt%, and 10 wt%; and 0 wt%, 5 wt%, and 10 wt%, respectively using Taguchi L9 orthogonal array. The particles displayed doping-induced colour variation. Powder X-ray diffraction (PXRD) analysis confirmed the samples' phase purity. Field effect-scanning electron microscopy (FE-SEM) and Transmission electron microscopy (TEM) were used to confirm the morphological similarity. Energy dispersive X-ray (EDX) analysis and Fourier transform–infrared (FT-IR) spectroscopy were used to ensure the chemical purity of the samples. To confirm the non-toxicity of samples, the MTT assay was utilized for MG-63 human osteosarcoma cells. All nine samples displayed cell viability greater than 80%. Additionally, the antibacterial properties were checked against S. aureus, S. pyogenes, E. coli and P. aeruginosa using the broth dilution method. The particles displayed comparable antibacterial properties against only E. coli bacterial strain. The obtained data of cell viability (%) and Optical density of broth against blank at 600 nm (OD600) for the antibacterial properties were analyzed using the Taguchi S/N ratio considering the larger-the-better case and smaller-the-better case, respectively. Based on the response table and ANOVA, it is inferred that the dopants’ concentration played the most significant role in controlling the cell viability and antibacterial properties. Since the Taguchi method can not simultaneously optimize two responses, multi-response optimisation will be considered in future studies.

Friction Stir Welding of Laser-powder Bed Fusion Manufactured A20X

This study investigates butt friction stir welding of 4 mm thick A20X plates, which were produced using additive manufacturing through laser-powder bed fusion. The plates were joined at varying process parameters, including different welding and rotational speeds. Both the microstructure and the mechanical strength of the joints were examined, comparing joints in both as-printed and as-welded conditions.The joints welded at a welding speed of 100 mm/min and a rotational speed of 1500 rpm exhibited superior mechanical properties compared to those produced with other parameter settings. The results show that decreasing the rotational speed while increasing the welding speed leads to the formation of tunnel defects, compromising joint integrity and resulting in lower ultimate tensile strength. In contrast, the combination of 100 mm/min welding speed and 1500 rpm rotational speed produced defect-free joints, with an average ultimate tensile strength of 335 MPa and an elongation at fracture of 8.5%.

Explaining the Anomaly Detection in Additive Manufacturing via Boosting Models and Frequency Analysis

Anomaly detection is an important feature in modern additive manufacturing (AM) systems to ensure quality of the produced components. Although this topic is well discussed in the literature, current methods rely on black-box approaches, limiting our understanding of why anomalies occur, making complex the root cause identification and the consequent decision support about the action to take to mitigate them. This work addresses these limitations by proposing a structured workflow designed to enhance the explainability of anomaly detection models. Using the wire arc additive manufacturing (WAAM) process as a case study, we examined 14 wall structures printed with INVAR36 alloy under varying process parameters, producing both defect-free and defective parts. These parts were classified based on surface appearance and welding camera images. We collected welding current and voltage data at a 5 kHz sampling rate and extracted features from both time and frequency domains using a knowledge-based approach. Isolation Forest, k-Nearest Neighbor, Artificial Neural Network, XGBoost, and LGBM models were trained on these features, and the results shown best performance of boosting models, achieving F1 scores of 0.927 and 0.945, respectively. These models presented higher performance compared to other models like k-Nearest Neighbor, whereas Isolation Forest and Artificial Neural Network posses lower performance due to overfitting, with an F1 score of 0.507 and 0.56, respectively. Then, by leveraging the feature importance capabilities of these models, we identified key signal characteristics that distinguish between normal and anomalous behavior, improving the explainability of the detection process and in general about the process physics.

Feasibility study on machine learning methods for prediction of process-related parameters during WAAM process using SS-316L filler material

The geometry of objects by means of wire arc additive manufacturing technology (WAAM) is a function of the quality of the deposited layers. The process parameters variation and heat flow affect the geometric precision of the parts, when compared to the actual dimensions. Therefore, in situ geometry monitoring which is integrated in such a way to enable a backward control model is essential in the WAAM process. In this article, an attempt is made to study the effect of four input variables, namely voltage (U), welding current (I), travel speed and wire feed rate on the output function in the form of two geometrical characteristics of a single weld bead. These output functions which are determinant of the weld quality are width of weld bead (BW) and height of weld bead (BH). A machine learning approach is utilised to predict the bead dimensions based on the input parameters and to predict the parameters by assigning suitable scores. For predicting the bead dimensions, two models, namely linear regression and random forest, shall be utilised, whereas for the purpose of classification based on weld parameters, k-nearest neighbours model shall be employed. Through this work, a wide dataset of parameters in the form of input variable and output in the form bead dimensions are generated for 316LSi filler material which shall be used as a training data for a machine learning algorithm. Subsequently, the predicted parameters shall be cross-checked with actual parameters.

Evaluation of chlorine and peroxyacetic acid efficacy in controlling Listeria innocua in a pilot-scale apple dump tank system

The dump tank and flume system, treated with antimicrobial sanitizers, is the first and most critical step to control the cross-contamination of foodborne pathogens on apples in commercial packing lines. Previous studies on the efficacy of chlorine and peroxyacetic acid (PAA) during apple washing have been primarily conducted in laboratory-scaled settings, which may not accurately reflect the efficacy of commercial dump tank operation due to variations in processing parameters. This study employed a pilot-scale dump tank system containing 102 L of pilot-simulated dump tank water (pSDTW) to evaluate the efficacy of chlorine and PAA in reducing Listeria innocua on apples and its cross-contamination between apples and water. Chlorine and PAA significantly reduced the transfer of L. innocua to uninoculated apples and water, with greater sanitizer concentrations and extended processing times enhancing their efficacy. Specifically, chlorine at 25–100 ppm free chlorine (FC) for 0.5–10 min resulted in the reductions of L. innocua by 0.4–1.1 log10 CFU/apple on inoculated apples and 3.5–5.4 log10 CFU/ml in inoculated pSDTW in the presence of 1000 ppm chemical oxygen demand (COD), leading to a transfer of 0.4–3.5 log10 CFU/apple to uninoculated apples. For PAA treatment, 20–80 ppm achieved reductions of 0.5–1.5 log10 CFU/apple on inoculated apples and 0.7–4.3 log10 CFU/ml in inoculated pSDTW, resulting in transfers of 3.5–4.2 log10 CFU/apple to uninoculated apples. Elevating the organic load in pSDTW from 1000 to 4000 ppm COD significantly reduced the effectiveness of chlorine in reducing L. innocua and its cross-contamination, and the anti-Listeria efficacy of PAA in water. This study provides valuable insights into optimizing dump tank operations for commercial apple packing lines.

A Mathematical Model for the Combination of Power Ultrasound and High-Pressure Processing in the Inactivation of Inoculated E. coli in Orange Juice.

The mathematical modeling of a combination of non-thermal technologies for E. coli inactivation is of great interest for describing the dynamic behavior of microorganisms in food, with the goal of process control, optimization, and prediction. This research focused on the design and implementation of a mathematical model to predict the effect of power ultrasound (US), high-pressure processing (HPP), and the combination of both non-thermal technologies on the inactivation kinetics of E. coli (DSM682) inoculated in orange juice. Samples were processed by US, HPP, and a combination of both technologies at varying process parameters, and a mathematical model for microbial inactivation was developed using a System Dynamics approach. The results showed that the combination of these technologies exhibited a synergistic effect, resulting in no detectable colony-forming units per mL of juice. The developed model accurately predicted the inactivation of E. coli following the combination of these technologies (R2 = 0.82) and can be used to predict microbial load reduction or optimize it based on process parameters. Additionally, combining both techniques offers a promising approach for extending the shelf life of fresh juices using non-thermal stabilization technology.

Evaluation of referral pathways for coronary artery bypass surgery patients; comparison on clinical outcomes, quality of life and process parameters

Objective To compare clinical outcomes, quality of life and process parameters of coronary artery bypass grafting (CABG) patients treated in a regional hub-and-spokes network. Methods Data from patients who underwent elective CABG from 2016 to 2020 at a Dutch heart center ('hub') were grouped by referral pathways by the cardiologist: internal (A) and four external (B–E). Clinical outcomes, quality of life, and process parameters were evaluated. Results In 690 CABG patients, no significant differences in baseline characteristics and clinical outcomes between care pathways were revealed. Hub-treated patients had shorter median hospital (7 days, IQR 6–8; p<.01) and preoperative stays (1 day, IQR 1–1; p<.01) compared to those treated at spokes. Within 8 weeks, 97.2% had outpatient visits, with pathways A, C, and E attending more frequently than B and D. Time to first visit ranged from 31–44 days. Cardiac rehabilitation began at 6 weeks for 40.4% of patients, with higher rates in Pathways B and D (66.4% and 50.0%) compared to the hub, C, and E (27.2% and 33.7%; p<0.001). Conclusion The study revealed notable variations in process parameters among different care pathways within a hub-and-spoke model for CABG patients, while maintaining comparable clinical outcomes and quality of life.

Microstructure and Properties of Gradient Ti(C,N)-Based Cermets by Powder Extrusion Additive Manufacturing

Ti(C,N)-based cermets are crucial for high-speed cutting tools and other high-temperature applications, yet there remains a considerable gap in their preparation controllability, fracture strength, and toughness compared to cemented carbide. Despite numerous studies having focused on modifying the hardness and toughness of Ti(C,N)-based cermets by varying process parameters and chemical compositions, this research has used gradient Ti(C,N)-based cermets produced by powder extrusion additive manufacturing (PEM) technology, which is rare. This study developed the gradient structure layer by layer using PEM. The microstructure of the printed and sintered parts was studied, and the hardness, fracture toughness, and bending strength of the gradient material were analyzed. The gradient material demonstrates superior mechanical properties compared to traditional Ti(C,N)-based cermets, with a hardness of 1760−23+39 HV20, a fracture toughness of 8.5−0.4+0.3 MPa·m1/2, and a bending strength of 2047−43+22 MPa. The research will assist researchers in assessing the potential application of PEM and broaden the application fields of gradient Ti(C,N)-based cermets.

Effect of Process Parameters on Yttria‐Stabilized Zirconia Particles In‐Flight Behavior and Melting State in Atmospheric Plasma Spraying

The preparation of coatings by atmospheric plasma spraying gives rise to complex physical processes, which present challenges to the study of plasma jet characteristics and particle in‐flight behavior. Herein, a 3D numerical model that integrates multiple physical phenomena, including electromagnetism and thermal and gas dynamics, to simulate the heating, acceleration, and melting of particles under the thermal–mechanical effect, is developed. Meanwhile, yttria‐stabilized zirconia (YSZ) coatings are prepared under varying process parameters. The DPV‐2000 system is employed for the diagnosis of particle velocity, surface temperature, and diameter. Following comparison, the simulation exhibits errors of 4.5% and 14.8% for the maximum temperature and velocity, respectively. An increase in current intensity from 500 to 600 A results in a rise in the proportion of particles exhibiting temperatures above the melting point (2963 K), from 75.1 to 93.4%, accompanied by an increase in average velocity of ≈16.6%. As the spraying distance increases from 60 to 100 mm, the proportion of particles melting decreases from 93.5 to 66.3%, and the average velocity decreases by ≈9.2%. This work will provide a theoretical foundation for the optimization of process parameters to adjust particle behavior and melting state, thus achieving an optimal spraying effect.