Numerical Modelling of Motion and Heating of Particles during Plasma Spraying

A theoretical model based on a CFD (computational fluid dynamics) methodology has been developed to simulate the motion and heating of particles in a plasma jet during plasma spraying. The particle motion and heat transfer equations are solved semianalytically using a prediction-correction method, taking into account phase changes during heating. The computational model is verified by experimental measurements and by comparison with experimental data in the literature. The results show that the relative motion between particles and the plasma jet has a major influence on particle heating through its influence on the heat transfer coefficient. The computational model can be used to predict the velocity, temperature, degree of melting, and trajectory of feedstock particles during practical plasma spraying.