Three-dimensional simulation of plasma jet and particle groups in plasma spraying

The temperature field, velocity field, as well as species distribution in three-dimensional space are successfully calculated by establishing three-dimensional geometry model and solving plasma jet-substrate interaction equations, optimized particle trajectory models, as well as particle-particle heat transfer equations in three-dimensional space. Under typical working conditions, the flying trajectories and distribution of ZrO₂ ceramic particles and Ni metal particles are also simulated. Results show that, the plasma jet becomes wider near the substrate, and the stochastic trajectory model is preferable to simulate the turbulent diffusion effect of particles. In addition, Ni metal particles penetrate relatively more deeply than ZrO₂ ceramic particles due to larger density.