Title: Effects of temperature-dependent viscosity, the impact parameters and substrate's conditions in the alumina splats deposition on stainless-steel substrates using atmospheric plasma spraying

Authors: Mohamed Elhoriny; Andreas Killinger; José Andrés Moreno Nicolás; Joaquín Solano Ramírez

Addresses: Tenneco, Engelschalkstraße 1, 86316 Friedberg, Germany ' Institute for Manufacturing Technologies of Ceramic Components and Composites, University of Stuttgart, Allmandring 7b, D-70569 Stuttgart, Germany ' Department of Mechanical Engineering, Materials and Manufacturing, Faculty of Industrial Engineering, Politechnic University of Cartagena, 30202 Cartagena, Spain ' Department of Thermal and Fluid Engineering, Faculty of Industrial Engineering, Politechnic University of Cartagena, 30202 Cartagena, Spain

Abstract: Thermal spraying technology has proved to be a reliable technique for depositing reproducible functional surface coatings with predefined dimensional tolerances and properties. To optimise the selection of the manufacturing parameters, numerical simulation is increasingly applied, because it can provide useful information in a short time. Directly observing the particle impact, spreading, and solidification is very difficult owing to the extremely short process time and size scale. In the study, the values for the thermal contact resistance, contact angle, high impact velocity, high impact temperature, and different substrate initial temperatures were addressed. The slip conditions at the splat-substrate interface were also considered through the creation of separate models using either Marangoni shear stress or no-slip conditions at the interface. The results obtained have been compared with experimental data. Finally, the effect of preheating the substrate on the droplet's dynamic viscosity is shown.

Keywords: APS; alumina coating; droplet flattening.

DOI: 10.1504/IJSURFSE.2024.138504

International Journal of Surface Science and Engineering, 2024 Vol.18 No.2, pp.172 - 188

Received: 13 Jul 2022
Accepted: 21 Oct 2022
Published online: 08 May 2024 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article