In this paper, a 3-D stochastic model is presented to predict the coating thickness and porosity in a thermal spray coating process. The model is based on prescribed rules in calculating the splat size during the impact of individual droplets on the substrate. Due to thermal stresses, the edge of the splats is curled up. This mechanism was assumed to be the sole reason for the porosity formation. Simulations are performed for a small section of a substrate on which a thermal spray of alumina droplets and other material particles are examined. The computed thickness and porosity were found to be in good agreement with those reported in the literature.

Keywords