Applications of numerical modelling techniques in thermal spray coatings: a comprehensive review

Thermal spray coating is a procedure that deposits many particles on the coating layer. This paper reviews thermal spray process numerical models. These models have both benefits and drawbacks. The future in the thermal coating process numerical simulation trends have been addressed in this article. The research closes with a numerical model analysis and development possibilities. FGCs solve traditional coatings' problems. It involves mathematical and computer simulations of FGC behaviour. To verify model accuracy, experimental data is compared to numerical model output. The numerical model shows stress distribution, thermal behaviour, and diffusion processes, allowing design optimisation. It also simplifies physics. FGC and numerical modelling can improve advanced engineering coating performance, durability, and functionality. Coatings can improve energy conversion, storage, and other applications. Future work includes using advanced numerical methods to increase model accuracy and creating new models for specialised purposes.