Simulation of PYSZ particle impact and solidification in atmospheric plasma spraying coating process

In this work a numerical model of the impact and solidification of partially yttria stabilized zirconia particles on flat and rough substrate surfaces under plasma spraying conditions and the simulation results are presented. Results of the numerical simulation showed the influence of particle diameter and particle state prior to impact on splats spreading behavior and final morphology. The particles have a diameter range from 20 µm to 60 µm. Particle initial conditions prior to impact: speed, temperature and melting state are taken from previous simulation approaches of particle acceleration and heating. Simulations of fluid dynamics, heat transfer and solidification during the particle impact were performed using computational fluid dynamics. Tracing of free surfaces was determined by the volume of fluid method. The simulation results are compared with several numerical and experimental studies of other scientists and showed good agreement. Simulated splat morphologies are compared with experimentally obtained splats. The numerical model shows good results under real coating conditions and is suitable for the implementation in industrial applications. This model builds a basis for calculation of microstructure during real coating processes and can be used not only for coating under atmospheric plasma spraying conditions but also for similar coating processes and diverse materials.