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Numerical Study of Suspension Plasma Spraying

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Abstract

A numerical study of suspension plasma spraying is presented in the current work. The liquid suspension jet is replaced with a train of droplets containing the suspension particles injected into the plasma flow. Atomization, evaporation, and melting of different components are considered for droplets and particles as they travel toward the substrate. Effect of different parameters on particle conditions during flight and upon impact on the substrate is investigated. Initially, influence of the torch operating conditions such as inlet flow rate and power is studied. Additionally, effect of injector parameters like injection location, flow rate, and angle is examined. The model used in the current study takes high-temperature gradients and non-continuum effects into account. Moreover, the important effect of change in physical properties of suspension droplets as a result of evaporation is included in the model. These mainly include variations in heat transfer properties and viscosity. Utilizing this improved model, several test cases have been considered to better evaluate the effect of different parameters on the quality of particles during flight and upon impact on the substrate.

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Author information

Authors and Affiliations

  1. Mechanical and Industrial Engineering Department, University of Toronto, Toronto, ON, Canada

    Amirsaman Farrokhpanah & Javad Mostaghimi

  2. Materials Science and Engineering, University of Toronto, Toronto, ON, Canada

    Thomas W. Coyle

Authors
  1. Amirsaman Farrokhpanah
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  2. Thomas W. Coyle
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  3. Javad Mostaghimi
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Correspondence to Amirsaman Farrokhpanah.

Additional information

This article is an invited paper selected from presentations at the 2016 International Thermal Spray Conference, held May 10-12, 2016, in Shanghai, P.R. China, and has been expanded from the original presentation.

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Farrokhpanah, A., Coyle, T.W. & Mostaghimi, J. Numerical Study of Suspension Plasma Spraying. J Therm Spray Tech 26, 12–36 (2017). https://doi.org/10.1007/s11666-016-0502-9

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