To predict the coating build-up and the microstructure of plasma sprayed TBCs, simulations are an advantageous tool. Because of the different scales which are involved in the spraying process different kinds of models must be used. We investigate the impact at small scale with a fluid dynamic model. For the simulation of coatings at large scale containing several hundred particles we use a Monte Carlo model, which is derived from the fluid dynamic model and verified by experiments.

The Monte Carlo model considers the given physical conditions, so that the spreading starts from the particle impact point and continues over the coating. The behaviour at steps or another kind of structured substrate can immediately be taken into account. The discretisation of the model is only lateral, so that the thickness of the coating perpendicular to the substrate is not limited.