基于熔滴多维统计的熔射涂层孔隙率模拟

Coating porosity simulation of plasma spray forming based on droplet multi-dimensional features

熔射成形涂层的微观结构,如孔隙的大小、形状、分布和涂层的表面粗糙度等,影响涂层的机械性能和物理性能,进而影响成形零件的使用性能。为方便研究熔射涂层成形过程以及成形工艺参数对涂层孔隙率的影响,本文以镍铝合金为例,依据熔滴薄片照片反映的形状特点生成数字化熔滴薄片,并结合熔滴时间和空间的多维统计特征模拟了熔射成形涂层的孔隙率。模拟涂层孔隙率为6.13%,与参考文献中相同条件下的实验结果5.7%比较接近。研究结果对熔射成形模具和零件的涂层质量控制具有参考意义。

The microstructure（such as pore size,shape,distribution,and surface roughness,etc.）of the coatings manufactured by plasma spray forming affects their physical and mechanical properties,and thereby affects the product quality and performance. To facilitate the study of spray forming process and the influence of spraying parameters on coating porosity,the microstructures of the plasma spray formed coatings are simulated based on the digital splat generated from the splat photo including its shape characteristics and multidimensional statistical characteristics such as time and space for consideration,and the nickel aluminum alloy is taken as an example. The porosity of the simulated coating is 6.13%,which is similar to the experimental results 5.7% under the same conditions according to the references. The results have referencial implications for the quality control of spray forming molds and parts.