An elastic-perfectly plastic model for simulating an aluminum particle behavior during plasma thermal spraying using the finite element method

► Time history of impact of an aluminum particle onto steel substrate has been carried out via Ansys software. ► Elastic-perfectly plastic material model is used instead of VOF model. ► Elastic and plastic strains, effective stress, contact pressure and energy densities are predicted. ► The effect of initial impact velocity has a significant effect on splat behavior. ► The mechanical model provides more insights into the dynamics of droplet impact.