Numerical Simulation of Plasma-Sprayed Functionally Graded Coatings

Based on the mass flux distribution and dispersion rules of molten particles onto the substrate in plasma spraying, the 3-D shape and 2-D composition distribution map of functionally graded coatings are simulated by employing the grid method and Monte Carlo stochastic model. The models simulate the stochastic deposition according to an appointed stochastic operation number, allowing for the calculation of a large number of plasma spraying particles of different materials. In the analysis, the final mass distribution of the calculated coating is consistent with the initial mass flux distribution and reveals the process of coating formation, as well as the potential mechanism of the composition distribution.