This paper presents a mathematical model of the in-flight oxidation of spherical particles during thermal spray deposition process. The model includes analysis of the mechanical and thermal behavior of the powder particles. The former accounts for acceleration and deceleration of the particles at the spray distance under different fluid velocities. The thermal behavior takes into account heating, melting, cooling and possible solidification as the particle travel towards the substrate. A finite-difference method is used to solve the thermal energy conservation equation of the particles. The model includes nonequilibrium calculations of the phase change phenomena in the liquid-solid (mushy) zone. The growth of the oxide layer at the particle surface is represented by a modified boundary condition, which includes finite-rate oxidation. The results obtained give the interrelations between various process parameters and the oxidation phenomenon and agree with experimental observation.

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