3-D time-dependent modelling of the plasma spray process. Part 1: flow modelling

The plasma spray process is widely used to produce thick coatings by the successive pilling of particles deposited in a molten or semi-molten state on a prepared substrate. However, this process includes time-dependent phenomena that affect the reliability of the process and reproducibility of coating. These phenomena are principally linked to the continuous movement of the electric arc root on the anode wall in the plasma gun. Such a movement leads to arc length variations resulting in fluctuations in arc voltage, enthalpy input to the flow and instabilities in the plasma jet. This paper presents an attempt to develop a time-dependent and 3-D model of the plasma spray process that can provide a useful insight in the time-evolution of the performance of the process. The effect of the transient behaviour of the arc on the gas flow is modelled with a time dependant heat source located inside the nozzle and evolving with the arc voltage. The first stage of the study consisted in the validation of the flow model thanks to the comparison of steady-state computed results with experimental data. The second dealt the time-dependant simulation of the flow.