A Confrontation of Lattice Boltzmann, Finite Difference and Taguchi Experimental Design Results for Optimizing Plasma Spraying Operating Conditions Toward Deposit Requirements

The aim of the present work is the confrontation of three numerical techniques results to optimize the operating conditions of thermal plasma spraying process. The Lattice Boltzmann method (LBM) is used to scrutinize dispersion effects of injection parameters on droplet impact characteristics when impacting substrate. The validation of the developed model shows good agreement with former findings. The results of spraying Zirconia particles give the values Kmin=88.2, Kmax=367.4, Kmean=273.8 and a standard deviation of 48.0 for the Sommerfeld number. The Taguchi experimental design study is conducted for five operating parameters of two levels. The ensuing retained factors combination give Kmean=258.9. To assess drawn conclusions, confirmation test was performed using the Jets&Poudres software. The results show that the prior way is to coat and particles of dp< 40.3 µm have evaporated, particles 40.3 = dp = 49 µm are fully molten and all particles of dp = 71.9 µm arrive fully solid.