Splats Formation, Interaction and Residual Stress Evolution in Thermal Spray Coating Using a Hybrid Computational Model

SPH simulation of YSZ and stainless-steel droplet impact for thermal spray process

“…As a result, the gridbased method induces expensive computational time and imprecision outcomes [17][18][19]. To resolve these issues, the particle-based Smoothed Particle Hydrodynamics (SPH) method has been employed to simulate the thermal spray process [20][21][22][23][24][25]. The SPH method is a mesh-free Lagrangian method for simulating fluid flows and natural phenomena that involve complex deformations, free surface flows, and moving particles.…”

“…The SPH method is a mesh-free Lagrangian method for simulating fluid flows and natural phenomena that involve complex deformations, free surface flows, and moving particles. Because of its advantage, the SPH method has been applied to study various multiphase fluid problems [18,[20][21][22][23][24][25][39][40][41][42][43][44]. The SPH method was applied to investigate the effects of contact angle and surface tension on the outcome of the YSZ droplet impact [20]; they found that the impact angle is less than 44°, and the droplet splash occurred.…”

“…But it has a severe mesh distortion and causes expensive computational time due to numerous problems in dealing with a free surface and moving interface [17][18][19]. To resolve these issues, the Smooth Particle Hydrodynamics (SPH) method is used to investigate the thermal spray process, and its applicability has been demonstrated in natural phenomena: complex deformation, free-surface movement, and fluid flow [20][21][22][23][24][25].…”

“…The splat behavior during and after impact is the most important feature in thermal spraying, and this phenomenon had been investigated in previous studies [20][21][22][23][24][25]. In order to mathematically predict impact outcome, this phenomenon can be characterized by the Sommerfeld parameter K. The Sommerfeld parameter K is defined by analyzing the phenomenon occurring when the droplet impinges on the substrate [46].…”

“…fluid flow phenomena such as obtaining time history, moving interface, large deformation, and free surfaces[18,[20][21][22][23]. The governing equation in which the Navier-Stokes equation is approximated in two stages, the fundamental integral representation and the particle approximation in the SPH method.…”