Study of Porous Materials Formation Through Semi-Molten Particle Deposition by Monte-Carlo Simulations

Porous materials possess many unique properties. Many processes have been employed to fabricate the porous materials. Recently, it was found that through controlled deposition of semi-melted spray powder particles a porous deposit can be created. In this study, a three-dimensional stochastic model was employed to simulate the formation process of porous materials through semi-molten particles deposition process to aim at predicting coating microstructure. The model is based on the Monte Carlo method. The spray particles are at different melting states and low velocity at which the rebound off after the impact of spray particles is negligible. The deposition test was performed for validation by using 316L stainless steel powder particles in different melting states which were controlled by flame spraying under different spray distances and acetylene flow rates. The results showed that the porous deposit with a porosity level over 60% can be deposited. The simulated results agree well with experimental observation.