Capturing the Influence of Jet Fluctuations on Particles in Plasma Spraying

Area of Science:

• Materials Science
• Plasma Physics
• Surface Engineering

Background:

• Plasma jet instabilities in thermal spraying affect particle behavior and coating quality.
• Accurate measurement of particle exposure to plasma conditions is crucial for process control.

Purpose of the Study:

• To develop and present a novel method for quantifying particle exposure to plasma jet conditions.
• To analyze the influence of plasma jet fluctuations on particle in-flight characteristics.

Main Methods:

• High-speed imaging of plasma jets from a cascaded three-cathode generator (TriplexPro-210).
• Image processing using the inverse Abel transform for accurate 3D plasma intensity reconstruction.
• Integration of processed images with computational fluid dynamics (CFD) simulated particle tracks.

Main Results:

• The developed method provides high temporal resolution data on plasma intensity experienced by individual particles.
• The technique successfully detected the influence of previously uncharacterized plasma jet fluctuations.
• Results highlight the sensitivity of the method in capturing subtle plasma dynamics.

Conclusions:

• The novel method offers precise characterization of particle-plasma interactions in thermal spray processes.
• Understanding these interactions is key to optimizing plasma-sprayed coating properties.
• The study demonstrates the significant impact of plasma jet stability on particle behavior.