In this study, a 3D two-way coupled Eulerian-Lagrangian approach is used to model the plasma jet and droplet-particle trajectory, velocity, and temperature achievable by suspension plasma spraying. A Reynolds stress model is used to account for turbulence and the effect of the substrate on the flow field and a Kelvin-Helmholtz Rayleigh-Taylor breakup model is used to predict the secondary breakup of the suspension. The focus of this work is on particle behavior near the substrate. Flat substrates placed at stand-off distances ranging from 40 to 60 mm are modeled to provide detailed information on particle impact behavior.

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