modeling the thermal spray process for the formation of surface coatings using the stochastic methods

in this paper, a 3d stochastic model has been presented to predict the coating thickness and porosity in a thermal spray coating process. different values of processing parameters were obtained. the model was developed on the basis of prescribed rules in calculating the splat size during the impact of individual droplets on the surface of the substrate. due to the thermal stresses produced during droplet solidification, splats were curled up in the edge regions. this mechanism was assumed to be the sole reason for the formation of porosity. the simulation was performed for a small section of the substrate. the calculated thickness and porosity were found to be in good agreement with the experimental results in this investigation, and with those already reported in the literature. the effects of different processing parameters including the gun distance from the substrate, the gun speed as well as the amount of powder feed rate on the coating properties were also investigated