Modeling of Suspension Plasma Spraying Process Including Arc Movement Inside the Torch
Suspension plasma spraying process, a relatively new deposition technique in thermal spray coating, has been increasingly applied to deposit high-quality thermal barrier coatings using submicron particles. An accurate simulation of the process includes the development of a realistic model of the plasma both within and outside the torch. In this work, a three-dimensional time-dependent model has been developed to simulate the magnetohydrodynamic fields inside a DC plasma torch including arc fluctuations. The Reynolds stress model is used to simulate the time-dependent turbulent plasma flow. To investigate the effects of plasma arc fluctuation on the trajectory, temperature, and velocity of suspension droplets injected into the plasma jet, a two-way coupled Eulerian–Lagrangian method is employed. Submicron yttria-stabilized zirconia particles, suspended in ethanol, are modeled as multicomponent droplets. The Kelvin–Helmholtz Rayleigh–Taylor breakup model is used to simulate the droplet breakup. Particles are also tracked after the completion of suspension breakup and evaporation to obtain the in-flight particle conditions including the trajectory, size, velocity, and temperature. The arc attachment spots showed a good agreement with the experimental images. It was also shown that the properties of the particles are significantly affected by plasma arc fluctuations.
Keywords3D unsteady plasma flow arc attachment electromagnetic fields suspension plasma spraying yttria-stabilized zirconia
Financial support from Green-SEAM, an NSERC Strategic Network Grant, is gratefully acknowledged.
- 2.A. Vardelle, C. Moreau, J. Akedo, H. Ashrafizadeh, C.C. Berndt, J. Oberste Berghaus, M. Boulos, J. Brogan, A.C. Bourtsalas, A. Dolatabadi, M. Dorfman, T.J. Eden, P. Fauchais, G. Fisher, F. Gaertner, M. Gindrat, R. Henne, M. Hyland, E. Irissou, B. Jodoin, E.H. Jordan, K.A. Khor, A. Killinger, Y.-C. Lau, C.-J. Li, L. Li, J. Longtin, N. Markocsan, P.J. Masset, J. Matejicek, G. Mauer, A. McDonald, J. Mostaghimi, S. Sampath, G. Schiller, K. Shinoda, M.F. Smith, A.A. Syed, N.J. Themelis, F.-L. Toma, J.P. Trelles, R. Vassen, and P. Vuoristo, The 2016 Thermal Spray Roadmap, J. Therm. Spray Technol., 2016, 25(8), p 1376-1440CrossRefGoogle Scholar
- 11.M. Jadidi, M. Mousavi, S. Moghtadernejad, and A. Dolatabadi, A Three-Dimensional Analysis of the Suspension Plasma Spray Impinging on a Flat Substrate, J. Therm. Spray Technol., 2015, 24, p 11-23Google Scholar
- 13.D. Khelfi, A. Abdellah El-hadj, and N. Ait-Messaoudène, Modeling of a 3D Plasma Thermal Spraying and the Effect of the Particle Injection Angle, Revue des Energies Renouvelables CISM’08 Oum El Bouaghi, 2008, 8, p 205-216Google Scholar
- 27.A. Boussagol, G. Mariaux, E. Legros, A. Vardelle, and P. Nulen, 3-D modeling of a DC plasma jet using different commercial CFD codes, Proceedings of 14th International Symposium on Plasma Chemistry, 2000Google Scholar
- 38.M. Alaya, C. Chazelas, G. Mariaux, and A. Vardelle, Arc-Cathode Coupling in the Modeling of a Conventional DC Plasma Spray Torch, J. Therm. Spray Technol., 2015, 24(1-2), p 3-10Google Scholar
- 41.Model SG-100 Plasma Spray Gun Operator’s manual, Manual Part Number: 05001760, Praxair Surface Technology, 2004Google Scholar
- 43.M.I. Boulos, P. Fauchais, and E. Pfender, Thermal Plasmas: Fundamentals and Applications, Springer, Berlin, 2013Google Scholar
- 44.ANSYS Inc., ANSYS FLUENT Theory Guide (USA, 2013), LinkGoogle Scholar
- 47.E. Pfender, R. Spores, and W.L.T. Chen, A New Look at the Thermal and Gas Dynamic Characteristics of a Plasma Jet, Int. J. Mater. Prod. Technol., 1995, 10, p 548-565Google Scholar
- 50.E. Ardakani, Numerical and Experimental Study of the Arc Fluctuations in a DC Plasma Torch, Ph.D. Thesis, University of Toronto, 2016Google Scholar