Abstract This paper investigates the layer formation in spray coating processes. Based on a Monte-Carlo simulation, a stochastic model of the coating layer thickness distribution was derived. It couples the stochastic process of droplet deposition on the particle surface with the droplet shape constructed from a spherical cap model and the droplets wetting properties (contact angle). The model was successfully shown to be able to replace the simulation. A parameter study revealed recommendations for designing a coating process, which were in agreement with the works from other authors. The model was then used to investigate the influence of overspray on the coating quality in comparison with experiments. It was found that the presence of overspray not only reduces the process efficiency but also increases the coefficient of variation of the resulting layer thickness distribution. This was caused by an increase in droplet size due to a predominant drying of small drops. It was also found, that a higher solid content of the spray solution increases the coefficient of variation, not only due to a decreased number of droplets, but also due to a greater variability in the layer thickness each droplet introduces.

中文翻译：

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涂层厚度分布的统计建模：过喷对涂层质量的影响

摘要 本文研究了喷涂工艺中的涂层形成。基于蒙特卡罗模拟，推导出涂层厚度分布的随机模型。它将液滴沉积在颗粒表面的随机过程与由球冠模型构建的液滴形状和液滴润湿特性（接触角）相结合。该模型已成功证明能够替代模拟。一项参数研究揭示了设计涂层工艺的建议，这些建议与其他作者的作品一致。然后使用该模型与实验进行比较，研究过喷对涂层质量的影响。发现过度喷涂的存在不仅降低了工艺效率，而且增加了所得层厚度分布的变异系数。这是由于小液滴主要干燥导致液滴尺寸增加所致。还发现，喷雾溶液的较高固体含量增加了变异系数，这不仅是因为液滴数量减少，而且还因为每个液滴引入的层厚变化更大。