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Trajectory Generation and Coupled Numerical Simulation for Thermal Spraying Applications on Complex Geometries

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Abstract

For high process reproducibility and optimized coating quality in thermal spray applications on complex geometries, atmospheric plasma spraying and high-velocity oxygen fuel torches are guided by advanced robot systems. The trajectory of the torch, the spray angle, and the relative speed between torch and component are crucial factors which affect the coating microstructure, properties, and, especially, the residual stress distribution. Thus, the requirement of high-performance thermally sprayed coatings with narrow dimensional tolerances leads to challenges in the field of robot-assisted handling, and software tools for efficient trajectory generation and robot programming are demanded. By appropriate data exchange, the automatically generated torch trajectory and speed profile can be integrated in finite element method models to analyze their influence on the heat and mass transfer during deposition. Coating experiments assisted by online diagnostics were performed to validate the developed software tools.

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Acknowledgments

The authors would like to thank Dr. José Andrés Moreno and Mr. Alejandro Frutos (Universidad Politécnica de Cartagena, Spain) for their important contribution to the development of tools for the simulation by FEM of the temperature distribution on free form surfaces.

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Authors and Affiliations

  1. Institute for Manufacturing Technologies of Ceramic Components and Composites (IMTCCC), University of Stuttgart, Stuttgart, Germany

    A. Candel & R. Gadow

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  1. A. Candel
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  2. R. Gadow
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Correspondence to A. Candel.

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Candel, A., Gadow, R. Trajectory Generation and Coupled Numerical Simulation for Thermal Spraying Applications on Complex Geometries. J Therm Spray Tech 18, 981–987 (2009). https://doi.org/10.1007/s11666-009-9338-x

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  • DOI: https://doi.org/10.1007/s11666-009-9338-x

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