Full-Scale Numerical Simulation of Plasma-Sprayed Functionally Gradient Materials

Abstract:

To develop novel and advanced thermal barrier coatings, full-scale numerical simulation of plasma-sprayed functionally gradient materials is conducted in this paper, including the prediction of basic parameters at the nozzle exit, simulation of three dimensional simulation of the plasma jet, modeling of the interaction between the plasma jet and the particles, calculation of flight trajectories and temperature history of flying metal and ceramic particles, the interaction between the molten particles and the substrate, as well as the deposition process of the coatings. Various complex phenomena, such as turbulent effects with chemical reactions in the plasma jet, dispersion status of the particles onto the substrate, and the composition distribution of the functionally gradient materials, are fully taken into account. The numerical simulation results are found to be in good agreement with experimental evidence.

• Periodical: Advanced Materials Research (Volume 75)
• Pages: 1-6
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.75.1
• Online since: June 2009
• Authors: Fu Chi Wang, Qun Bo Fan, Lu Wang, Quan Sheng Wang, Zhuang Ma
• Keywords: Full-Scale Simulation, Functionally Graded Material (FGM), Plasma Spraying

References

[1] K. A. Khor, Z. L. Dong, Y. W. Gu. Plasma sprayed functionally gradient thermal barrier coatings. Materials Letters. 38 (6) (1999) p.437.

DOI: 10.1016/s0167-577x(98)00203-1

[2] A. Kawasaki, R. Watanabe. Thermal fracture behavior of metal/ceramic functionally gradient materials. Engineering Fracture Mechanics. 69(14) (2002) p.1713.

DOI: 10.1016/s0013-7944(02)00054-1

[3] R. C. Reid, J. M. Prausnitz, T. K. Sherwood. The properties of gases and liquids．The 4th Edition．New York: McGraw-Hill, (1987).

[4] Y. Y. Zhao, P. S. Grant, B. Cantor. Modelling and experimental analysis of vacuum plasma spraying. Part I: prediction of initial plasma properties at plasma gun exit. Modelling Simulation of Materials Science and Engineering. 8 (2000) p.497.

DOI: 10.1088/0965-0393/8/4/308

[5] J. Mckelliget, J. Szekely, M. Vardelle et al. The temperature and velocity fields in a gas steam exiting a plasma torch．Plasma Chemistry and Plasma Processing, 2 (1982) p.317.

DOI: 10.1007/bf00566526

[6] B. E. Launder, D. B. Spalding. Lectures in Mathematical Models of Turbulence．London: Academic Press, (1972).

[7] B. F. Magnussen, B. H. Hjertager. On mathematical models of turbulent combustion with special emphasis on soot formation and combustion．In 16th Symp. on Combustion．USA: The Combustion Institute, (1976).

DOI: 10.1016/s0082-0784(77)80366-4

[8] K. F. Chen, J. R. Fan. Theory and calculation of industrial gas and solid multi-phase fluid. Hang Zhou: Press of Zhe Jiang University, 1990 (in Chinese).

[9] J. Q. Hallquist. LS-DYNA Theoretical Manual Livermore Software Technology Corporation, Livermore, (1988).

[10] Q. B. Fan, L. Wang, F. C. Wang. A Study on transient pressure of plasma sprayed metal/ceramic particles. Transactions of Beijing Institute of Technology. 23(2) 2003 p.168.

[11] Q. B. Fan, L. Wang, F. C. Wang et al. Modeling of composite coatings in plasma spraying. Surface & Coatings Technology. 201 (16-17) 2007 p.6977.

DOI: 10.1016/j.surfcoat.2007.01.011