The Influence of the Substrate Topography on the Plasma Jet Flow and Particle Deposition as a Determining Factor of Thermal Barrier Coatings Build-Up Mechanisms in Plasma Spraying

Abstract

The aim of this work is to better understand the build-up of thermal barrier coatings (TBC) on microtextured substrates, particularly the influence of geometry on the behavior of plasma jets in substrate boundary layers. Coatings produced by suspension plasma spraying served as an experimental reference for numerical analysis, which involved advanced turbulent flow and volumetric heat source modeling along with the use of commercial fluid flow software. Geometric and numerical models were used to simulate the generation of plasma inside the torch and the resulting plasma flow with its highly nonlinear thermophysical characteristics. This work opens the possibility of predicting feedstock particle movement and deposition, which is essential in understanding coating build-up mechanisms in general and the flow of fine particles on substrate surfaces in particular.

The Numerical Analysis of the Trajectory and Landing Location of YSZ Droplets Impinging the Microtextured Substrate

“…The maximum values of the respective BC for each section are shown in Table 1. The entire domain simulation is more widely discussed in the previous studies (Ref 10,33) considering the plasma generation, free-jet flow, and the interaction between the plasma jet and the microtextured substrate. Figure 6 shows the scheme of computational domain BCs related to the plasma flow and the coating material modeling.…”

Experimental and Numerical Analysis on a Thermal Barrier Coating with Nano-Ceramic Base: A Potential Solution to Reduce Urban Heat Islands?

“…From the latest state of the art in this field, most research focuses on the chemical designing of the best Thermal Barrier Coating (TBC) to achieve the best mechanical, thermal, environmental, and durability performances [2][3][4][5][6][7]. The research goals are often to better understand the development or fabrication process of TBC materials or to improve their performances for high temperatures, with the most current applications being gas turbines or automobile coatings [8][9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24]. Liu et al [11] listed the five principal nanomaterial classes used to make TBCs and described their characteristics and preparation methods [11]: oxides, perovskites, pyrochlores, magnetoplumbites, and high-entropy ceramics.…”