Effect of initial impact velocity on dynamics and shape of formed splats of hollow droplets in thermal plasma spraying

Applications of hollow spherical particles in industry and in thermal spraying process have been developed in recent years. Despite dense droplets, in hollow droplets, the volume changes of the gas play an important role in the dynamics of impact and the shape of the formed splats. In plasma thermal spraying, impact velocities of particles to the surface is in the range of 50 m/s-300 m/s, therefore, changes in pressure and volume of the trapped gas, is important. In this research, impact of hollow droplet on a flat surface and its solidification has been simulated. Volume of fluid model for compressible flows at real thermal spraying condition is used while the impact velocities in the range of 50 m/s-300 is considered. In a few moments after the impact of droplet on the surface, a pressure wave is formed in the air. This wave, increase the vorticity in vicinity of interface of two fluid, which has a great effect on shaping the formed splats. Simulations showed that shape of formed splats vary with velocities in the range of 50 m/s-300 m/s. In higher velocities, the surface of the formed splat is more porous.