Homogenization of Coating Properties in Atmospheric Plasma Spraying – New Results of a DFG (German Research Foundation)-Funded Research Group

Abstract In order to homogenize the properties of APS sprayed coatings, the spray process was investigated using numerical simulations combined with innovative diagnostic techniques. The process was subdivided into three areas: the plasma torch, the free jet, and coating formation. By simulating these areas separately and combining the results, appropriate process parameters for homogenized coatings were obtained. For a comprehensive computation of coating formation which, besides the impact, flattening, and solidification of particles, includes the mechanical properties of the coating, a volume of fluid algorithm is coupled with a finite element model. In order to verify the modeling of the plasma jet and to provide input data for the coating formation, diagnostic efforts were concentrated on measuring the gas temperature of the plasma as well as particle shape, velocity, and temperature. The results of spatially resolved 3D analysis employing an innovative tomography system are presented and compared with the numerical results.