TY - JOUR

T1 - Modelling the Plasma Jet in Multi-Arc Plasma Spraying

AU - Bobzin, K.

AU - Öte, M.

AU - Schein, J.

AU - Zimmermann, S.

AU - Möhwald, K.

AU - Lummer, C.

N1 - Funding Information: The authors gratefully acknowledge the financial support of the German Research Foundation (DFG) within the project “Homogenization of Coating Properties in Atmospheric Plasma Spraying” (PAK 193/BO1979/7-2). This paper is partially based on chapters 3 and 5 in M. Öte, “Understanding Multi-Arc Plasma Spraying,” Shaker-Verlag, RWTH Aachen, Dissertation, ISBN: 978-3-8440-4598-7.

PY - 2016/8/1

Y1 - 2016/8/1

N2 - Particle in-flight characteristics in atmospheric plasma spraying process are determined by impulse and heat energy transferred between the plasma jet and injected powder particles. One of the important factors for the quality of the plasma-sprayed coatings is thus the distribution of plasma gas temperatures and velocities in plasma jet. Plasma jets generated by conventional single-arc plasma spraying systems and their interaction with powder particles were subject matter of intensive research. However, this does not apply to plasma jets generated by means of multi-arc plasma spraying systems yet. In this study, a numerical model has been developed which is designated to dealing with the flow characteristics of the plasma jet generated by means of a three-cathode spraying system. The upstream flow conditions, which were calculated using a priori conducted plasma generator simulations, have been coupled to the plasma jet simulations. The significances of the relevant numerical assumptions and aspects of the models are analyzed. The focus is placed on to the turbulence and diffusion/demixing modelling. A critical evaluation of the prediction power of the models is conducted by comparing the numerical results to the experimental results determined by means of emission spectroscopic computed tomography. It is evident that the numerical models exhibit a good accuracy for their intended use.

AB - Particle in-flight characteristics in atmospheric plasma spraying process are determined by impulse and heat energy transferred between the plasma jet and injected powder particles. One of the important factors for the quality of the plasma-sprayed coatings is thus the distribution of plasma gas temperatures and velocities in plasma jet. Plasma jets generated by conventional single-arc plasma spraying systems and their interaction with powder particles were subject matter of intensive research. However, this does not apply to plasma jets generated by means of multi-arc plasma spraying systems yet. In this study, a numerical model has been developed which is designated to dealing with the flow characteristics of the plasma jet generated by means of a three-cathode spraying system. The upstream flow conditions, which were calculated using a priori conducted plasma generator simulations, have been coupled to the plasma jet simulations. The significances of the relevant numerical assumptions and aspects of the models are analyzed. The focus is placed on to the turbulence and diffusion/demixing modelling. A critical evaluation of the prediction power of the models is conducted by comparing the numerical results to the experimental results determined by means of emission spectroscopic computed tomography. It is evident that the numerical models exhibit a good accuracy for their intended use.

KW - CFD

KW - computed tomography

KW - LES

KW - modelling

KW - multi-arc spraying

KW - numerical analysis

KW - plasma jet

KW - turbulence

UR - http://www.scopus.com/inward/record.url?scp=84979497561&partnerID=8YFLogxK

U2 - 10.1007/s11666-016-0438-0

DO - 10.1007/s11666-016-0438-0

M3 - Article

AN - SCOPUS:84979497561

VL - 25

SP - 1111

EP - 1126

JO - Journal of Thermal Spray Technology

JF - Journal of Thermal Spray Technology

SN - 1059-9630

IS - 6

ER -