A Coupled Model Between Robot Trajectories and Thermal History of the Workpiece During Thermal Spray Operation

Offline robot trajectory generation is now often used for thermal spray applications, especially for complex design parts, requiring enhanced trajectories. This technique allows decreasing the downtime of the thermal spray cell and insures the generation of optimized trajectories. Heat transfers caused by thermal spray increase the workpiece temperature during the coating application. This temperature acts directly on the resulting thermal stresses after cooling of the part down to the ambient temperature. In this study, a coupling was developed between the robot trajectory and computation of the thermal history of the workpiece during the spray operation. The method is based on the storage of the real robot trajectory (i.e., accurate in time) in a text file, and reading of this file with a C programming performed with ANSYS/FLUENT commercial code which allows computing the displacement of the thermal sources according to the trajectory and solving the transient heat conservation equation during the torch displacement. The contributions of the impinging plasma jet and the molten particle jet are taken into account in the model.