Scaling analysis and prediction of thermal aspects of the plasma spraying process using a discrete particle approach

On the basis of a discrete particle approach, a scaling analysis was used to predict features of the thermal plasma spraying process. Correlations were obtained using the analysis and they were subsequently used to predict two important features: the state of the particle at the moment of impact on the substrate, and the nature of solidification process. Limitations and restrictions were also identified in the development of the analysis that can be used to infer the resulting structure of coating. The correlations that were developed might be utilized in optimizing the thermal plasma spraying process, as well as in producing new types of coatings.