Evaluations of ceramic spraying processes by numerical simulation

A plasma spraying process from ceramic particle injection to coating formation was evaluated computationally by integrating particle-laden plasma flow, splat formation and coating formation models. Since the plasma flow is unsteady, radial distributions of particle impact temperature and the particle impinging point are obtained. The particle impact temperature is effectively increased by applying an RF electromagnetic field. Furthermore, the coating thickness distribution is strongly influenced by particle size and the RF electromagnetic field.