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A Numerical Study of Suspension Injection in Plasma-Spraying Process

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Abstract

Suspension feedstock in plasma spraying opened a new chapter in coating process with enhanced characteristics. The suspension carrying sub-micron up to few micron-sized particles is radially injected into an atmospheric plasma plume. Understanding the trajectory, velocity, and temperature of these small particles upon impacting on the substrate is a key factor to produce repeatable and controllable coatings. A three dimensional two-way coupled Eulerian-Lagrangian scheme is utilized to simulate the flow field of the plasma plume as well as the interactions between the evaporative suspension droplets with the gas phase. To model the breakup of droplets, Kelvin-Helmholtz Rayleigh-Taylor breakup model is used. After the breakup and evaporation of suspension is complete, the solid suspended particles are tracked through the domain to determine the characteristics of the coating particles. The numerical results are validated against experiments using high-speed imaging.

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Acknowledgments

The authors would like to acknowledge the significant contribution of Dr. Fadhel Ben Ettoui (research assistant in the thermal spray laboratory, Concordia University) and Dr. Bernard Pateyron (research engineer SPCTS Limoges, France) for preparing the T&TWinner data bank to calculate the physical properties of materials. This study was financially supported by Fonds de recherche du Québec (FQRNT).

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Concordia University, Montreal, QC, Canada

    F. Jabbari, M. Jadidi, R. Wuthrich & A. Dolatabadi

Authors
  1. F. Jabbari
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  2. M. Jadidi
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  3. R. Wuthrich
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  4. A. Dolatabadi
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Corresponding author

Correspondence to A. Dolatabadi.

Additional information

This article is an invited paper selected from presentations at the 2013 International Thermal Spray Conference, held May 13-15, 2013, in Busan, South Korea, and has been expanded from the original presentation.

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Jabbari, F., Jadidi, M., Wuthrich, R. et al. A Numerical Study of Suspension Injection in Plasma-Spraying Process. J Therm Spray Tech 23, 3–13 (2014). https://doi.org/10.1007/s11666-013-0030-9

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  • DOI: https://doi.org/10.1007/s11666-013-0030-9

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