A new heat transfer based finite element model is proposed to simulate coating thickness in the electron-beam physical vapor deposition (EB-PVD) process. The major advantage of the proposed model is that it is much computationally efficient than the traditional ray-tracing based model by about two orders of magnitude. This is because the Gaussian distribution heating source has the same profile as the cosine relation used in the ray-tracing method. Firstly, the model simulates the temperature profile of a metal substrate heated by a heating source with a Gaussian distribution. Then using a calibrated conversion process, the temperature profile is converted to corresponding coating thickness. The model is successfully demonstrated by three validation cases, including a stationary disk, a stationary cylinder, and a rotary three-pin component. The predicted coating thicknesses in the validation cases are in good agreement with either the ray-tracing based analytical solution or experimental data. After its validation, the model is applied to a rotary turbine blade to predict its coating thickness distribution. In summary, the model is capable to simulate coating thickness in complex shaped parts.

提出了一种新的基于传热的有限元模型，以模拟电子束物理气相沉积（EB-PVD）过程中的涂层厚度。所提出的模型的主要优点是，与传统的基于光线跟踪的模型相比，它的计算效率要高两个数量级。这是因为高斯分布加热源的轮廓与射线追踪方法中使用的余弦关系相同。首先，该模型模拟了由具有高斯分布的加热源加热的金属基板的温度曲线。然后，使用校准的转换过程，将温度曲线转换为相应的涂层厚度。通过三个验证案例成功地证明了该模型，包括固定盘，固定圆柱体和旋转三销组件。在验证案例中，预测的涂层厚度与基于射线追踪的分析解决方案或实验数据非常吻合。在验证之后，将模型应用于旋转涡轮叶片以预测其涂层厚度分布。总之，该模型能够模拟复杂形状零件的涂层厚度。