A model of the shock-wave induced spray process (SISP) and the criteria for bonding are used to predict whether particles traveling within the unsteady flow regime will adhere to the substrate upon impact. The results are then used to predict if a coating can be formed under specific spraying conditions. Having been validated based on particle velocity measurements, the model is used to investigate the effect of varying spray parameters, such as powder and gas initial temperature, gas heater length, and spray frequency.

This paper describes the development and testing of an emulator representing a single-cathode atmospheric plasma torch. The emulator consists of three subsystems: input, simulator, and output. Arc current intensity, the hydrogen ratio of the forming gas, and its total mass flow rate are taken as input parameters, while in-flight particle temperature and velocity are the designated output. The simulator was developed in a two-stage process. By collecting and analyzing experimental data, a mathematic model expressing plasma torch operation was defined. The model was then tested and compared with experimental data. It is shown to be relatively accurate with an average error of about 2.2% in particle temperature and 1.1% in velocity.

This paper presents a method for optimizing plasma spraying parameters based on statistical analysis and related models. The models presented account for particle velocity and plasma mass enthalpy and make it possible to study the influence of plasma properties on the deposition process.