Determination of temperature distribution within polyurethane substrates during deposition of flame-sprayed aluminum-12silicon coatings using Green's function modeling and experiments

Deposition of coatings on polymer-based substrates by using the thermal spraying process is a challenging task due to the thermal sensitivity of polymer materials and the high temperatures that are typical of thermal spraying processes. Thus, prediction of the temperature distribution in the substrate during spraying is considered a key factor in the selection of appropriate coating materials and control of process parameters. In this study, a mathematical model, based on a Green function approach, has been developed to predict the temperature distribution within polymeric substrates during flame spraying. Good agreement was obtained between the experimental measurements and the computed results. The model was further utilized to study the effect of air pressure and the stand-off distance of the flame spray torch on the temperature distribution in the substrate. In addition to validating the model with experimental results, it was also validated through comparison of its predictions with those of an established model.