In this study, the bonding formation of the cast iron splat deposited on a preheated aluminum substrate by atmospheric plasma spraying was investigated using a finite element method based on a heat transfer model built in a cylindrical coordinate system. To enhance the accuracy of calculations, thermal contact resistance ( R th ) of the contact interface was incorporated into the calculation. A precise R th value was obtained using a well-established relationship. The diameter of grains in the splat was determined by atomic force microscopy analysis. Furthermore, the physical parameters of the cast iron and the aluminum at different temperatures used in the simulation were calculated according to the composition of the materials. The calculations indicated that the interface temperature was below the substrate melting point during the entire observation period, confirming that no melting of the aluminum substrate had occurred. Thus, the formation of splat–substrate metallurgical bonding was attributed to the enhanced interface temperature and plastic deformation rather than the melting of the substrate surface.

中文翻译：

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使用基于实验的数值模拟方法研究等离子喷涂铸铁板在预热铝基板上的结合形成

在这项研究中，基于圆柱坐标系中建立的传热模型，使用有限元方法研究了通过大气等离子喷涂在预热的铝基板上沉积的铸铁板的结合形成。为了提高计算的准确性，计算中加入了接触界面的接触热阻（R th ）。使用完善的关系获得精确的 R th 值。通过原子力显微镜分析确定片中晶粒的直径。此外，根据材料的成分计算了模拟中使用的铸铁和铝在不同温度下的物理参数。计算表明，在整个观察期间界面温度低于基板熔点，确认没有发生铝基板的熔化。因此，splat-基体冶金结合的形成归因于界面温度和塑性变形的提高，而不是基体表面的熔化。