Efficient stochastic simulation of thermal spray processes

In this report we present novel extensions to a simulation model by Ghafouri et al. concerning plasma spraying. The extensions include a physically inspired splat spreading approach, a method to generate splat fingers, and a filtering technique that allows for the calculation of pores below overlapping splats. Furthermore, features characterizing coatings beyond the commonly used porosity or surface roughness are presented and analyzed with respect to their appropriateness. Features are considered appropriate if they are depending in a unique way on the parameters of the simulation model. This kind of features might be used in an automatic adaptation of the simulation model to real processes. Finally, several contributions are made in order to increasing the computational efficiency of the simulation. Most important, dexel models are introduced to represent the coating.