Heat Transfer in Suspension Plasma Spraying

  • Mehdi Jadidi
  • Armelle Vardelle
  • Ali Dolatabadi
  • Christian Moreau
Reference work entry


Suspension plasma spraying (SPS) is an emerging thermal spray processes. Its specific feature is to use a suspension that is a heterogeneous mixture of very fine particles in an aqueous or organic solvent, to achieve finely structured coatings. The latter have a great potential for demanding applications like solid-oxide fuel cells or thermal barriers in gas turbines. The suspension feedstock is injected radially or axially into a DC plasma jet in the form of a spray of droplets with size of 20–200 μm or a continuous jet. The interaction of the suspension drops/jet with the high-temperature high-velocity plasma jet results in their fragmentation into small droplets and vaporization of solvent in a few microseconds. Subsequently, the solid particles are accelerated, heated, and melted by the plasma jet and rapidly flatten and solidify after impact on the substrate. Although this process has been investigated for about 20 years, the effect of process operation parameters and mechanisms are not fully understood yet. In this chapter, the phenomena involved in suspension plasma spraying process, the basic aspects in the simulation of this process, as well as the main technological challenges are described in detail. Different correlations for suspension properties, liquid penetration height in gaseous crossflow, effervescent atomizers, droplet/particle drag coefficient, and Nusselt number, as well as the importance of coating particles’ Stokes number are discussed. Moreover, various methods for plasma jet modeling, the specific volume of fluid approach for modeling the liquid-plasma jet interaction, the commonly used secondary breakup models, and an approach for modeling suspension droplet based on a multicomponent assumption are reviewed.


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Copyright information

© Springer International Publishing AG, part of Springer Nature 2018

Authors and Affiliations

  • Mehdi Jadidi
    • 1
  • Armelle Vardelle
    • 2
  • Ali Dolatabadi
    • 1
  • Christian Moreau
    • 1
  1. 1.Department of Mechanical and Industrial EngineeringConcordia UniversityMontrealCanada
  2. 2.European Ceramic Center, Laboratoire Sciences des Procédés Céramiques et de Traitements de SurfaceUniversity of LimogesLimoges CedexFrance

Section editors and affiliations

  • Javad Mostaghimi
    • 1
  1. 1.Department of Mechanical and Industrial EngineeringUniversity of TorontoTorontoCanada

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