Abstract
The aim of this study is to model a spray process that combines aspects of plasma and HVOF spraying. The process is characterized by its stability over a broad range of fuel-oxidant conditions and ability to produce coatings using relatively little gas with rather low gross heating values The mathematical model developed accounts for the formation of the plasma jet, the combustion process, and supersonic flow issuing from the spray torch. Simulating the new process made it possible to investigate the effect of the plasma on the velocity and temperature of the gas flow inside and outside the gun. The equations were solved using CFD code and predictions were compared with experimental observations. The benefits of the plasma jet are discussed on the basis of predictions and fuel combustion mechanisms.