This study aims to develop high-fidelity computational
models to predict the coating thickness on complex-shaped components. In this
work, two types of models, i.e., ray-tracing based and heat transfer
based, are developed. For the ray-tracing model, assuming a line-of-sight
coating process and considering the shadow effect, validation studies of
coating thickness predictions on different shapes, including plate, disc,
cylinder, and three-pin components. For the heat transfer model, a heat source
following the Gaussian distribution is applied. It has the analogy of the
governing equations of the ray-tracing method, thus generating a temperature
distribution similar to the ray intensity distribution in the ray-tracing
method, with the advantages of high computational efficiency. Then, using a
calibrated conversion process, the ray intensity or the temperature profile are
converted to the corresponding coating thickness. After validation studies,
both models are applied to simulate the coating thickness in a rotary turbine
blade.
The results show that the simulated validation cases are in good agreement with either the experimental , analytical, or modeling results in literature. The turbine blade case shows the coating thickness distribution based on rotating speed and deposition time. In summary, the models can simulate the coating thickness in rotary complex - shaped parts, which can be used to design and optimize the coating deposition process.
