Title: Formation of coating layers in low and high velocity molten hollow particles impact in thermal spray coating deposition process

Authors: Rajesh Kumar Shukla; Arvind Kumar

Addresses: Department of Mechanical Engineering, IIT Kanpur, Kanpur 208016, India ' Department of Mechanical Engineering, IIT Kanpur, Kanpur 208016, India

Abstract: Thermal spray coating technology is used to produce protective coatings for wear, thermal, oxidation, and corrosion environments. The quality of the coating depends on the droplet impact process on the substrate in which individual splats are formed. This work focuses on computational analysis of the impact behaviour of a hollow droplet onto a substrate with low and high impact velocity and the resulting formation of the splat layer. It has been shown that the droplet's impact process, spreading and solidification behaviour for the hollow and analogous continuous droplets are distinctly different. A phenomenon of counter liquid jetting occurs during the hollow droplet impact and spreading which is well-validated with the experiment. This phenomenon is found to occur with both the low and the high velocity hollow droplet's impact. It has been also shown that this phenomenon is responsible for formation of uniform and thick splat layers in the coating for the hollow droplet.

Keywords: thermal spray deposition; molten particles; droplet impact; solidification; computational fluid dynamics; simulation; CFD; layer formation; coating layers; hollow particles; thermal spray coating.

DOI: 10.1504/IJMTM.2013.058629

International Journal of Manufacturing Technology and Management, 2013 Vol.27 No.1/2/3, pp.74 - 87

Received: 02 Apr 2013
Accepted: 24 Sep 2013
Published online: 29 Apr 2014 *

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