The objective of this research is to quantitatively analyze and model how the wire
material is heated, melted, atomized, transported, and deposited onto the substrate: Knowledge of
fluid flow in the wire-arc gun is necessary to predict the size and shape of the primary
detachments from the wire-tips. Knowledge of particle properties and their distributions is
needed because it directly affects the quality of the produced coating. Knowledge of individual
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particle deposition (and splat formation) is necessary because it determines the microstructure of
the produced coating layer.
As different industrial applications of thermal sprays require different ranges of particle
velocities, particle temperatures, and particle sizes, the ultimate goal of this research is to use the
obtained knowledge and suggest methods of controlling/enhancing the wire-arc process and
make it more suitable for each application.