Abstract
The properties of the coatings produced by plasma spraying are essentially related to the adhesion force between the projected particles and the substrate. The melting of the substrate can significantly improve this adhesion strength. In this paper, a 2D axisymmetric model was developed to simulate the impact of a fully melted particle of alumina in droplet form on an aluminum substrate, taking into consideration the melting of the substrate and its re-solidification using Ansys Fluent 14. Equations of fluid dynamics and energy including phase change are solved in a structured mesh by finite volume discretization. The volume of fluid method (VOF) is used for tracking the free surface of the droplet. An enthalpy-porosity formulation is used to model the solidification. The effect of the initial temperature of the droplet on the melting of the substrate has been studied. Substrate fusion was observed before the droplet spread completely. The volume of molten substrate increases over time, to reach its maximum, then it begins to decrease because of its re-solidification. The substrate is completely solidified well after the solidification of the droplet. It has been observed that the volume of the molten substrate is greater when the initial temperature of the droplet is important, which can improve the adhesion strength of the coating.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Pawlowski L (2008) The science and engineering of thermal spray coatings, 2nd edn. John Wiley & Sons Ltd, Chichester, UK
Fauchais P, Montavon G, Vardelle M, Cedelle J (2006) Developments in direct current plasma spraying. Surf Coat Tech 201:1908–1921
Chandra S, Fauchais P (2009) Formation of solid splats during thermal spray deposition. J Therm Spray Technol 18:148
Li CJ, Li CX, Yang GJ, Wang YY (2006) Examination of substrate surface melting induced splashing during splat formation in plasma spraying. J Therm Spray Technol 15(4):717–724
Goutier S, Vardelle M, Fauchais P (2012) Understanding of spray coating adhesion through the formation of a single lamella. J Therm Spray Technol 21:522
Kang CW, Tan JK, Pan L, Low CY, Jaffar A (2011) Numerical and experimental investigations of splat geometric characteristics during oblique impact of plasma sparying. Appl Surf Sci 257:10363
Tabbara H, Gu S (2012) Modelling of impingement phenomena for molten metallic droplets with low to high velocities. Int J Heat Mass Transf 55:2081
Oukach S, Hamdi H, El Ganaoui M, Pateyron B (2015) Numerical study of the spreading and solidification of a molten particle impacting onto a rigid substrate under plasma spraying conditions. Therm Sci 19:277–284
Zhang H (1999) Theoretical analysis of spreading and solidification of molten droplet during thermal spray deposition. Int J Heat Mass Transf 42(14):2499–2508
Bussmann M, Chandra S, Mostaghimi J (2000) Modeling the splash of a droplet impacting a solid surface. Phys Fluids 12(12):3121–3132
Pasandideh-Fard M, Chandra S, Mostaghimi J (2002) A three-dimensional model of droplet impact and solidification. Int J Heat Mass Transf 45:2229
Jiang XY, Wan YP, Wang XY, Zhang H, Goswami R, Herman H, Sampath S (2000) Investigation of splat/substrate contact during Molybdenum thermal spraying. In: Berndt CC (ed) Thermal spray: surface engineering via applied research, ASM International, Materials Park, pp 729–36
Wang SP, Wang GX, Matthys EF (1999) Deposition of a molten layer of high melting point material: substrate melting and solidification. Mater Sci Eng, A 262:25–32
Zarzalejo LJ, Schmaltz KS, Amon CH (1999) Molten droplet solidification and substrate remelting in microcasting—part I: numerical modeling and experimental verification. Heat Mass Transf 34:477–485
Zhang H, Wang XY, Zheng LL, Jiang XY (2001) Studies of splat morphology and rapid solidification during thermal spraying. Int J Heat Mass Transf 44(24):4579–4592
Li L, Wang XY, Wei G, Vaiday A, Zhang H, Sampath S (2004) Substrate melting during thermal spray splat quenching. Thin Solid Films 468:113–119
Rajesh KS, Arvind K (2015) Substrate melting and re-solidification during impact of high-melting point droplet material. J Therm Spray Technol
Brackbill JU, Kothe DB, Zemach C (1992) A continuum method for modeling surface tension. J Comput Phys 100:335
Voller VR, Prakash CA (1987) Fixed-grid numerical modeling methodology for convection-diffusion mushy region phase-change problems. Int J Heat Mass Transf 30:1709–1720
Aziz SD, Chandra S (2000) Impact, recoil and splashing of molten metal droplets. Int J Heat Mass Transf 43:2841–2857
Wang SP, Wang GX, Matthys EF (1998) Melting and resolidification of a substrate in contact with a molten metal: operational maps. Int J Heat Mass Transf 41(10):1177–1188
Keshri AK, Agarwal A (2011) Splat morphology of plasma sprayed aluminum oxide reinforced with carbon nanotubes: a comparison between experiments and simulation, Surf Coat Technol
Acknowledgements
Our thanks for the USTHB Fluid Mechanics Laboratory.
For allowing us to use Ansys Fluent 14.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2020 Springer Nature Switzerland AG
About this paper
Cite this paper
Driouche, M., Rezoug, T., El-Ganaoui, M. (2020). Effect of Droplet Initial Temperature on Substrate Melting and Its Re-solidification in Plasma Spray Process. In: Chaari, F., et al. Advances in Materials, Mechanics and Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-24247-3_14
Download citation
DOI: https://doi.org/10.1007/978-3-030-24247-3_14
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-24246-6
Online ISBN: 978-3-030-24247-3
eBook Packages: EngineeringEngineering (R0)