Thermal Spray and Multiphase Flow Laboratories
Department of Mechanical and Industrial Engineering

Numerical Study of Suspension Injection in Plasma Spraying Process


Farzad Jabbari, M.A.Sc student

Mehdi Jadidi, PhD candidate

Dr. Ali Dolatabadi


Dr. Rolf Wuthrich, Concordia University



Suspension feedstock in plasma spraying opened a new chapter in the coating process with enhanced characteristics. The suspension carrying sub-micron up to few micron particles is radially injected into an atmospheric plasma plume. . Understanding the trajectory, velocity, and temperature of these small particles upon impacting on the substrate is a key factor to produce repeatable and controllable coatings. To this end, the suspension penetration in the plume, the suspension evaporation, trajectory and temperature, and the effect of the suspension flow rate are numerically studied


Figure 1 : Geometry and boundary conditions

The next figure shows the effect of the suspension mass flow rate on the gas phase velocities when the suspension mass flow rate increases from 0.25 g/s to 0.5 g/s. as the suspension mass flow rate increases (so the momentum force increases), the penetration in the plasma plume grows and the gas phase velocity in this region decreases.


Figure 2 : The comparison between gas velocities obtained by RSM and KHRT models when mass flow rates are 0.25 g/s (case a) and 0.5 g/s (case b)

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