Skip to main content
SpringerLink
Log in

Analysis of the Microstructure of Thermal Spray Coatings: A Modeling Approach

  • Peer Reviewed
  • Published:
Journal of Thermal Spray Technology Aims and scope Submit manuscript

Abstract

Microstructure of coatings produced by thermal spray coating process depends on many parameters, including particle impact conditions, powder materials, and substrate conditions. Because of the large number of parameters affecting microstructure, developing a computational tool that can predict the microstructure of thermal spray coatings as a function of these parameters can be of great interest as it will save time and resources when developing new coatings. In this article, we examine the validity and the accuracy of such a computational tool. We present the result of a three-dimensional model of coating formation. The model is based on the Monte Carlo method with particle impact conditions, materials properties of powder, and substrate as input. The output of the model includes coating porosity, surface roughness, and coating thickness. In order to validate the model, coatings under specific conditions were deposited and the predicted results were compared to the actual deposits. The impact conditions for these cases were measured by DPV-2000 and the raw data were used as input to the computer program. The comparison between the actual deposits and the simulated ones shows good agreement. The results demonstrate the viability and usefulness of this modeling tool in developing new coatings and understanding their microstructure.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

Notes

  1. The particle conditions at specific locations on the scanning grid are measured by DPV2000. During these measurements, the position of the torch is fixed during plasma coating operation; however, plasma torch is moving and is not stationary. Therefore, at each time step, the measured particles’ positions by DPV2000 are adjusted to correspond to the new position of the plasma gun and the center of the scanning grid.

References

  1. R. Ghafouri-Azar, J. Mostaghimi, S. Chandra, and M. Charmchi, A Stochastic Model to Simulate the Formation of Thermal Spray Coating, J. Thermal Spray Technol., 2003, 12(1), p 53-69

    Article  ADS  Google Scholar 

  2. R. Ghafouri-Azar, J. Mostaghimi, and S. Chandra, Modeling Development of Residual Stresses in Thermal Spray Coatings, Comput. Mater. Sci., 2006, 35, p 13-26

    Article  CAS  Google Scholar 

  3. R. Ghafouri-Azar, S. Shakeri, S. Chandra, and J. Mostaghimi, Numerical Simulation of Offset Deposition for Sequential Tin Droplet, Proceeding of International Thermal Spray Conference and Exposition, March 4-6, 2002 (Germany), 2002, p 951-959

  4. M. Xue, S. Chandra, and J. Mostaghimi, Investigation of Splat Curling Up in Thermal Spray Coatings, J. Thermal Spray Technol., 2006, 15(4), p 531-536

    Article  CAS  ADS  Google Scholar 

  5. M. Xue, S. Chandra, J. Mostaghimi, and C. Moreau, A Stochastic Coating Model to Predict the Microstructure of Plasma Sprayed Zirconia Coatings, Modell. Simul. Mater. Sci. Eng., 2008, 16(6), p 19

    Article  MATH  Google Scholar 

  6. Y. Kawai and Y. Shiraishi, Handbook of Physico-Chemical Properties at High temperatures, Iron and Steel Institute of Japan, 1988, p xxi

  7. K. Shinoda, Y. Kojima, and T. Yoshida, In Situ Measurement System for Deformation and Solidification Phenomena of Yttria-Stabilized Zirconia Droplets Impinging on Quartz Glass Substrate Under Plasma Spraying Conditions, J. Thermal Spray Technol., 2005, 14(4), p 511-517

    Article  CAS  ADS  Google Scholar 

  8. G. Mauer, R. Vaßen, and D. Stövre, Atmospheric Plasma Spraying of Yttria-Stabilized Zirconia Coating with Specific Porosity, Surf. Coat. Technol., 2009, 204, p 172-179

    Article  CAS  Google Scholar 

  9. H. Chen, S.W. Lee, H. Du, C.X. Ding, and C.H. Choi, Influence of Feedstock and Spraying Parameters on the Depositing Efficiency and Microhardness of Plasma-Sprayed Zirconia Coating, Mater. Lett., 2004, 58, p 1241-1245

    Article  CAS  Google Scholar 

  10. OOF: Finite Element Modeling for Materials Science, NIST, http://www.nist.gov/msel/ctcms/oof/

  11. J. Mostaghimi, S. Chandra, R. Ghafouri-Azar, and A. Dolatabadi, Modeling Thermal Spray Coating Processes: A Powerful Tool in Design and Optimization, Surf. Coat. Technol., 2003, 163-164, p 1-11

    Article  CAS  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Simulent, Inc., Toronto, ON, Canada

    Hamideh B. Parizi

  2. Centre for Advanced Coating Technologies, Faculty of Applied Science and Engineering, University of Toronto, Toronto, ON, Canada

    Javad Mostaghimi, Larry Pershin & Hamid S. Jazi

Authors
  1. Hamideh B. Parizi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Javad Mostaghimi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Larry Pershin
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Hamid S. Jazi
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Javad Mostaghimi.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Parizi, H.B., Mostaghimi, J., Pershin, L. et al. Analysis of the Microstructure of Thermal Spray Coatings: A Modeling Approach. J Therm Spray Tech 19, 736–744 (2010). https://doi.org/10.1007/s11666-010-9494-z

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11666-010-9494-z

Keywords

Search

Navigation