Development of an Alternative to the Plasma Cladding Process: the Plasma Spray Melting Technology

Compared to traditional plasma cladding technology, plasma spray melting technology is characterized by a small heat-affected zone and high processing speed, and has a high application value. However, the process still faces significant problems, such as inaccurate parameters and work points and feasibility that need to be investigated. This study discusses a two-dimensional (2D) model of the plasma spray melting process to provide a theoretical basis for determining the optimal process parameters. The spray melting process was studied in depth by considering the cooling effect of gas convection on the melting pool, as well as by the analysis of thermal cycling and thermal diffusion of the matrix. Finally, the reliability of the model was validated by a Ni60 coating with micro-metallurgical bonding characteristics, which was spray melted onto the surface of a Q235 steel matrix. Due to its characteristics of low power, fast heating, and fast cooling, plasma spray melting technology can be used to prepare various thin coatings with micro-metallurgical bonding on the die surface, so as to significantly improve the bonding strength of the coating and mitigate the influence of the heat of the spray melting process on the die, thereby improving the material performance.