Understanding multi-arc plasma spraying

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Multi-arc plasma spraying systems offer several advantages over conventional single-arc systems, yet many fundamental aspects remain poorly understood. While extensive numerical research has been applied to single-arc plasma spraying, similar efforts have not been directed toward multi-arc systems. This thesis presents a comprehensive numerical study aimed at understanding the behavior of plasma columns in the torch and powder particles in the plasma jet during multi-arc plasma spraying. The research emphasizes the impact of numerical aspects and model assumptions on the results. Intensive verification of the necessary models for analyzing plasma and particle behavior has been conducted, ensuring their accuracy against underlying assumptions. The prediction capabilities of these models were assessed by comparing their results with those from advanced diagnostic systems. The study analyzes general characteristics of plasma columns and particle behaviors within the plasma jet using the developed numerical models. Additionally, potential application areas for these models are highlighted. The models demonstrate good accuracy in predicting plasma jet characteristics, particle temperatures, and velocities. Given the stable behavior of the plasma columns, the modeling of multi-arc spraying systems offers a reliable description of the process, enabling effective design and optimization of process and injection parameters.