Advanced Diagnostics and Modeling of Spray Processes

Abstract

The microstructure and properties of thermally sprayed deposits depend critically on the thermal- and kinetic-energy histories of the particles entrained in the hot-gas jet. At impact, the particle temperature, molten fraction, size, velocity, and chemistry, along with substrate temperature and surface characteristics, control the morphology of individual particle splats. These factors control the adhesion, strength, microstructure, and porosity of a coating and influence the residual-stress state. In order to produce higher-quality coatings and expand the use of this versatile family of technologies, the ability to model and measure particle behavior is essential.