Numerical Modeling of Selected Thermal Spraying Issues

Thermal spraying is one of the most universal techniques for depositing feedstock materials on a substrate. It allows the production of metallic, ceramic, and composite coatings on both metallic and ceramic substrates. Spray deposition involves ejecting heated or cold particles of feedstock material at high velocity toward the substrate. In the final stage of the process, the substrate and the formed coating are cooled to ambient temperature, resulting in residual stresses due to differences in the thermal, physical, and mechanical properties of the feedstock materials and the substrate. The residual stress state of the coating and substrate has a significant effect on their strength, thermal shock resistance, and fatigue life under cyclically varying thermal loads.