Air plasma spraying is a variation of thermal spraying that is used, among others, for the production of thermal barrier and wear resistant coatings. High plasma temperatures enable the processing of ceramic powder particles which have a high melting point and cannot be processed otherwise. Due to their low heat conductance, the ceramic particles are not necessarily fully melted during their flight in the free jet and prior to the impact on the substrate surface. Experimental particle temperature measurements by means of particle diagnostics systems deliver merely the surface temperature of the particles while the melting degree of the ceramic particles remains unknown. Therefore, the temperature field within spherical Al2O3 particles is numerically investigated for a commonly used particle size distribution by considering different particle sizes. The model includes a two-way coupled particle-laden free jet model and takes the latent heat of melting and evaporation into account. The effect of the particles size as well as the stand-off distance on the melting degrees of the particles in the given powder size distribution is determined.

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