In the recent decade, considerable numerical models have been built up to simulate the thermal spray process. However, much less work has focused on the prediction of thermo-physical properties of the thermal spray coating, in particular the heat insulation properties. In this paper, a microstructure integrated finite element model is developed to investigate the heat insulation behavior of the thermal spray coating. A two-layer model is used to calculate thermal conductivity of the coating, where one layer stands for the coating by a unit cell, while another one for a standard material with known thermal conductivity. In the proposed unit cell model, pores and unmelted particles are assumed spherical and randomly distributed, and the interface between the coating and the unmelted particles is perfectly debonding. Based on the predictions, the effect of the pores, unmelted particles, cracks and their respective distributions on the heat insulation behavior of the coating has been further discussed in the paper.

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