Trajectory Generation and Coupled Numerical Simulation for Thermal Spraying Applications on Complex Geometries
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. Candel and R. Gadow (Submitted January 13, 2009; in revised form April 19, 2009) For high process reproducibility and optimized coating quality in thermal spray applications on complex geometries, atmospheric plasma spraying and high-velocity oxygen fuel torches are guided by advanced robot systems. The trajectory of the torch, the spray angle, and the relative speed between torch and component are crucial factors which affect the coating microstructure, properties, and, especially, the residual stress distribution. Thus, the requirement of high-performance thermally sprayed coatings with narrow dimensional tolerances leads to challenges in the field of robot-assisted handling, and software tools for efficient trajectory generation and robot programming are demanded. By appropriate data exchange, the automatically generated torch trajectory and speed profile can be integrated in finite element method models to analyze their influence on the heat and mass transfer during deposition. Coating experiments assisted by online diagnostics were performed to validate the developed software tools.
Keywords
diagnostics and control, influence of process parameters, modeling, processing, robotics and automation in thermal spraying
element method (FEM) can be used to model temperature distribution, residual stresses, and coating growth. By the interconnection of the tools for trajectory generation with numerical simulation of the coating process, the influence of the jet movement on the heat transfer during deposition can be evaluated.
1. Introduction The development of innovative software tools for the virtual production of coatings is one of the most promising fields in modern production engineering by thermal spraying. In this multidisciplinary field, the analysis of the influence of the jet trajectory on the coating properties as well as the numerical simulation of heat and mass transfer during deposition should be included. The automatic generation of improved robot trajectories for the production of coatings with narrow dimensional tolerances on complex surfaces is a further aim. A crucial issue therefore is the development of flexible software tools for trajectory generation on complex geometries and time saving off-line robot programming. Due to the influence of the robot trajectory, speed profile, and coating angle on the residual stress distribution and coating quality, modules for process simulation should be integrated and coupled with the tools for trajectory generation. The simulation of the coating process involves computational fluid dynamics (CFD) for calculation of gas and particle properties as well as heat flux on the component during coating. Additionally, simulations by finite A. Candel and R. Gadow, Institute for Manufacturing Technologies of Ceramic Components and Composites (IMTCCC), University of Stuttgart, Stuttgart, Germany. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
2. Influence of Torch Handling on Coating Properties and Residual Stress Distributi
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