Thermal spray technology implies different scales of physical phenomena which occur simultaneously during coating deposition process. Hence, the particular process cannot be analyzed by the deployment of a single numerical model. Despite that, the entire spraying process must be divided into sub-processes, which should be modeled using different approaches.
Below is some results from our previous work of developing a digital replica (Digital Twin) for Cold Gas Dynamic Spray process (CGDS). CGDS is a unique coating technology in which spray particles in a solid-state are deposited on a substrate, via high-velocity impact, at temperatures lower than the melting point of the powder materials and thereby prevent in-flight oxidation of feedstock materials.
Here are the results of computational fluid dynamic (CFD) analysis illustrated a velocity of carrier gas along with the velocity distribution of powder feedstock materials.