Research And Modeling On Energy Consumption Of Plasma Spraying Process

Plasma spraying technology can extend the service life of parts and complete the market circulation of remanufactured parts through the surface repair of high-value parts.However,the plasma spraying process has the disadvantages of high energy consumption and low energy utilization.Therefore,it is of great significance for further research on the process and energy consumption of plasma spraying technology.Based on this,the energy consumption model of plasma spraying system was established and studied in this paper:(1)A process energy consumption model was established by using UPLCI analysis method to quantitatively characterize the relationship between process parameters and process energy consumption of equipment.The verification test showed that the prediction error of energy consumption was less than 5%.Various power states of plasma spraying were studied by orthogonal test.The results show that the order of influence of process parameters on energy consumption was power>track distance>spray gun moving speed,and the power had the greatest influence on energy consumption.The influence order of process parameters on coating performance was:power>powder feeding rate>gun moving speed>track distance,in which power and powder feeding rate were the main factors.The relationship between energy consumption and coating performance was studied.It was found that there were different characterizations of coating performance under the same process energy consumption,which was due to the same energy consumption and different coating performance under different combinations of parameters.(2)The single pass coating thickness distribution function of beta distribution was improved.By analyzing the influence of process parameters on coating thickness,the relationship between height,power,main gas flow and spray width was established,and the relationship between thickness,spray gun speed,track distance,powder feeding rate,power,main gas flow and thickness parameters was established.The single pass coating thickness distribution function was established by theoretical derivation and experimental fitting.By analyzing the effect of track distance on coating thickness superposition,a coating thickness distribution model for plasma spraying process was established,and the model error was controlled within 15%.(3)Based on the energy consumption and thickness model,the energy efficiency mathematical model of the process was determined.It was found that the influence order of the process parameters on the energy efficiency was:power>lance moving speed>track distance>main gas flow>powder feeding rate.The relationship between energy efficiency and coating properties was analyzed.It was found that the energy efficiency and hardness decreased first and then increased.The energy efficiency was inversely proportional to the thickness and had no obvious relationship with porosity.TOPSIS multi-objective optimization method was used to solve the multi-objective optimization of energy efficiency,thickness,hardness and porosity.The consistency of weight distribution is tested by AHP multi-level analysis method.The optimal results of the 20th group of experimental schemes are obtained.The optimal process parameters are as follows:power 35 kW,powder feeding rate 2.4 r/min,spray gun speed 150 mm/s,track distance 3.0 mm,main air flow 3400 L/h.