Rapid evaluation of temperature distribution of coatings during atmospheric plasma sprayed process

This study presents the experimental results of coating AISI 1045 steel substrate by low alloyed carbon steel powder using atmospheric plasma spraying (APS). Thermocouples were used to monitor the temperature history at specified positions during the spraying process. A simplified thermal finite element model of APS coating is presented. The transient temperature field is calculated first. An appropriate numerical filter implementing the thermal time response of the thermocouple is created and applied to the raw FEM results. Agreement between experiment and numerical model for temperature were deemed promising despite the simplifications adopted in the numerical model.