Riddhi Joshi, Benjamin Boesl, Arvind Agarwal, Tony Thomas
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Desktop Manufacturing of Plasma-Sprayed Coating and Computational Estimation of its Mechanical Properties
Traditional optimization of plasma-sprayed coatings involves resource-intensive experimental iterations of spraying parameters. This study presents a novel computational protocol for designing and manufacturing ceramic (e.g., Al2O3) coatings, reducing the need for extensive experiments. A computational fluid dynamics approach is adopted to simulate the morphology of Al2O3 powder feedstock splats. These simulated splats are then stochastically arranged to construct three-dimensional (3D) representations of plasma-sprayed Al2O3 coatings. The effective elastic modulus of the coating is computed using finite element analysis of the simulated microstructure. The introduced "Desktop Manufacturing Protocol" showcases a significant reduction in the requisite plasma spraying experiments, offering an optimized coating with desired microstructure and mechanical properties. This integrated computational approach not only streamlines the coating development process but also provides insights into the intricate relationships between spraying parameters, microstructure, and overall coating performance.
期刊介绍:
From the scientific to the practical, stay on top of advances in this fast-growing coating technology with ASM International''s Journal of Thermal Spray Technology. Critically reviewed scientific papers and engineering articles combine the best of new research with the latest applications and problem solving.
A service of the ASM Thermal Spray Society (TSS), the Journal of Thermal Spray Technology covers all fundamental and practical aspects of thermal spray science, including processes, feedstock manufacture, and testing and characterization.
The journal contains worldwide coverage of the latest research, products, equipment and process developments, and includes technical note case studies from real-time applications and in-depth topical reviews.