Simulation of thermally sprayed coating properties considering the splat boundaries

Bobzin, Kirsten; Heinemann, H.; Wolf, Franz; Wietheger, Wolfgang

doi:10.1088/1757-899x/1147/1/012026

Cited by 3 publications

(4 citation statements)

References 9 publications

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“…All the more interesting are the scaling implications for the simulation of multiple droplet impacts. The increased performance allows for faster iteration times when simulating multiple droplets as well as significantly more accurate res-olution of gaps in the coating on the scale of < 1 µm, than was possible before by Bobzin et al [17].…”

Section: Discussionmentioning

confidence: 99%

“…In previous works of the authors the particle impact and solidification was modeled using a modified momentum source approach [15] which was then applied to simulate multiple particle solidification [16]. The most recent work presents a calculation of the effective thermal conductivity using information of inter-splat gaps derived from a simulation of multiple splats of Al 2 O 3 droplets [17]. However, while the experimental results showed the characteristic length of the gaps to be < 1 µm, the simulation could only resolve gaps with a width of its cell size of 2.25 µm.…”

Section: Previous Workmentioning

confidence: 99%

“…A 3D thermal spray coating build-up model based on a previous publication of the authors [17] was created and implemented in Ansys Fluent. In this model, the impact of thermally sprayed ceramic droplets onto a flat substrate was simulated.…”

Section: Ansys Fluentmentioning

confidence: 99%

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Application and benchmark of SPH for modeling the impact in thermal spraying

et al. 2022

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The properties of a thermally sprayed coating, such as its durability or thermal conductivity depend on its microstructure, which is in turn directly related to the particle impact process. To simulate this process, we present a 3D smoothed particle hydrodynamics (SPH) model, which represents the molten droplet as an incompressible fluid, while a semi-implicit Enthalpy-Porosity method is applied for modeling the phase change during solidification. In addition, we present an implicit correction for SPH simulations, based on well-known approaches, from which we can observe improved performance and simulation stability. We apply our SPH method to the impact and solidification of Al$$_2$$ 2 O$$_3$$ 3 droplets onto a substrate and perform a comprehensive quantitative comparison of our method with the commercial software Ansys Fluent using the volume of fluid (VOF) approach, while taking identical physical effects into consideration. The results are evaluated in depth, and we discuss the applicability of either method for the simulation of thermal spray deposition. We also evaluate the droplet spread factor given varying initial droplet diameters and compare these results with an analytic expression from the previous literature. We show that SPH is an excellent method for solving this free surface problem accurately and efficiently.

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Section: Discussionmentioning

confidence: 99%

Section: Previous Workmentioning

confidence: 99%

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Application and benchmark of SPH for modeling the impact in thermal spraying

et al. 2022

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“…The part needs excellent compatibility and adhesion to the coating [10]. In addition, the design of a coating system, including the coating type, number of layers and thickness will also significantly affect the durability of the coating [11][12][13]. Surface anticorrosion of machining parts plays an important role in equipment parts, which influence the properties of parts.…”

Section: Introductionmentioning

confidence: 99%

Modeling the Interfacial Bonding Strength of Al-Zn-Si Alloy between Substrates with Linear Surface Roughness and Its Coating

Man

et al. 2023

Coatings

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Interfacial bonding strength between the substrate and its coating is one of the important indexes affecting the service life of parts. To reduce the manufacturing cost, a mathematical model can be established to quantitatively describe the microscopic surface roughness and its anti-corrosion coating adhesion strength. Anti-corrosion life could be improved by controlling the surface roughness of the substrate. In this study, a model of interfacial bond strength and roughness, which was calibrated using the substrate surface and closely related to the cell spacing and length of the support, was established. Under the same condition as the coating, component materials and the coating thickness, results were obtained that the coating strength changed along with the substrate roughness. When roughness changed between 37.1 μm and 48.4 μm, the bonding strength showed a decreasing trend. The larger the value of the roughness, the more conducive it was to the bonding between the arc spraying layer and the substrate. The adhesion between the coating and substrate was not always increased with the higher roughness on the same surface. It should be evaluated based on the surface roughness and its evaluation parameters, and there was an optimal roughness evaluation and selection range. The experimental results were consistent with the theoretical predictions.

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Modeling the Droplet Impact on the Substrate with Surface Preparation in Thermal Spraying with SPH

et al. 2023

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The properties of thermally sprayed coatings depend heavily on their microstructure. The microstructure is determined by the dynamics of the impact of the droplets on the substrate surface and the subsequent overlapping of the previously solidified and deformed droplets. Substrate preparation prior to spraying ensures strong adhesion of the coating. This includes roughening and preheating of the substrate surface. In the present study, the smoothed particle hydrodynamics (SPH) method is used to model the Al2O3 impact on a preheated substrate and a roughened substrate surface. A semi-implicit enthalpy–porosity method is applied to simulate the solidification process in the mushy zone. In addition, an implicit correction for SPH simulations is used to improve the performance and stability of the simulation. To investigate the dynamics of heat transfer in the contact between the surface and the droplet, the discretization of the substrate is also taken into account. The results show that the studied substrate surface conditions affect the splat morphology and the solidification process. Subsequently, the simulation of multiple droplets for coating formation is also performed and analyzed.

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Simulation of thermally sprayed coating properties considering the splat boundaries

Cited by 3 publications

References 9 publications

Application and benchmark of SPH for modeling the impact in thermal spraying

Application and benchmark of SPH for modeling the impact in thermal spraying

Modeling the Interfacial Bonding Strength of Al-Zn-Si Alloy between Substrates with Linear Surface Roughness and Its Coating

Modeling the Droplet Impact on the Substrate with Surface Preparation in Thermal Spraying with SPH

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