Research Status on Numerical Simulation of Plasma Spraying Coating in Micro-forming Process
DING Shuyu1, MA Guozheng1, XU Binshi1, WANG Haidou1, CHEN Shuying1,2, HE Pengfei1, WANG Yiwen1
1 National Key Laboratory for Remanufacturing, Army Academy of Armored Forces, Beijing 100072 2 National Key Laboratory of Human Factors Engineering, China Astronaut Research and Training Center, Beijing 100094
Abstract: Plasma spraying is characterized by the high temperature of flame flow, fast particle velocity and high energy density, which is one of the common surface engineering techniques for surface strengthening and remanufacturing of parts and has important applications in many fields, such as wear-resisting, anti-corrosion and thermal barrier. The service performance and life of the product is often determined by the quality of the coating. The forming quality of plasma spraying coating is determined by the cross-coupling of many spray elements and process parameters. The traditional method of optimizing spraying process is to determine the feasible region of main process parameters according to practical experience, which has to adjust the progress parameters and test the performance of the coating over and over again. This method has the disadvantage of high cost, low efficiency and poor reliability. Numerical simulation is a high-efficiency, low-cost scientific research method. In the field of plasma spraying, it can not only optimize the spraying process parameters, but also help deeply understand the principle of spray forming and the process of coating microcosmic construction. With the help of numerical simulation, the researchers have explored the microscopic mechanism of the plasma spraying process, the transient and high-speed phenomena which could not be observed in experiment. What’s more, it can also guide the optimization of spray process parameters, improve the mechanical structure of the spray gun, and play an important role in improving the coating quality and performance. This paper summarizes the research steps of finite element simulation in numerical simulation and reviews the micro-forming process of plasma sprayed coating in recent research state of numerical simulation. As for the numerical simulation of plasma jet formation, the research field has transformed from a single physics field to a multi-physics coupling. By this mean, it can accurately grasp the complex physical phenomena in plasma spray guns. The numerical simulation ranges includes temperature field simulation of plasma jet, turbulent flow simulation, and electromagne-tic characteristic simulation. For the numerical simulation of the interaction between spray particles and jets, the researchers have explored the influence of spraying particles and atmospheric physical parameters on the flight process in combination with experiments, and obtained the best spraying distance, powder feed tube angle and other technological parameters. The numerical simulation ranges include particle acceleration simulation, heating process simulation, flight track and spatial distribution simulation in plasma jet. In the numerical simulation of the solidification and spreading process of sprayed particle, it can visualize the instantaneous, high-speed spread solidification process, and grasp the influence of substrate and atmospheric physical parameters on the process. The numerical simulation ranges includes the simulation of impact deposition process and the solidification growth process of particle. There are some problems in the numerical simulation, which are the inaccuracy of the turbulence model, the superficial research on the evaporation and fragmentation phenomena of flying-particles, and the less exploration of multiple particles overlap stacking processes. It prospects the research direction of the numerical simulation in the micro-forming process of plasma coatings and proposes the conception of establishing a virtual coating forming system, which is based on the numerical simulation of the spray forming process.
丁述宇, 马国政, 徐滨士, 王海斗, 陈书赢, 何鹏飞, 王译文. 等离子喷涂层微观成形过程数值模拟研究现状[J]. 材料导报, 2019, 33(11): 1889-1896.
DING Shuyu, MA Guozheng, XU Binshi, WANG Haidou, CHEN Shuying, HE Pengfei, WANG Yiwen. Research Status on Numerical Simulation of Plasma Spraying Coating in Micro-forming Process. Materials Reports, 2019, 33(11): 1889-1896.
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