Numerical study of semi-molten droplet impingement

Due to the low thermal conductivity of ceramics large temperature gradients are present through the powder particles during plasma spray deposition. As a result the particles often impinge at the substrate in a semi-molten form; which in turn substantially affects the final characteristics of the coating being formed. This study is dedicated to the novel modelling development and simulation of a semi-molten droplet impingement. The study examines the impingement process during impact, spreading and solidification of semi-molten zirconia. The simulation provides an insight to the heat transfer process during impact and solidification of a semi-molten powder particle and illustrates the freezing-induced break-up mechanism at the splat periphery.