This paper presents a mathematical model of the plasma-spray coating formation process that allows one to estimate bond strength energy, a parameter related to coating quality. Bond strength energy is defined on the basis of particle-substrate or system balance. Unknown quantities in the energy equation are obtained from nonstationary Navier-Stokes equations for velocity field and pressure and from thermoelasticity equations for temperature and stress. Complexities associated with particle spreading and nonlinear hydrodynamics have made it necessary to develop a stable numerical technique.

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