目的 分析等离子喷涂熔滴在表面织构内的铺展、凝固规律，为了解表面织构化对等离子喷涂涂层结合机制的影响以提升涂层的结合强度提供理论辅助。方法 基于Flow 3D 建立熔滴填充微织构的数值模型，研究等离子喷涂熔滴填充正弦形织构的温度场及铺展成形规律，并对比分析织构边缘凸起及织构形状的影响。同时，基于激光织构化表面等离子喷涂试验，分析不同织构对涂层形貌的影响。结果 无边缘凸起织构的散热速度比有边缘凸起织构的快约0.7 μs，凹坑织构的散热速度最慢，计算结束时，其最高温依然高于熔滴液相线(1728.4 K)约44.7 K。基体最高温度约1680.5 K，其主要分布于织构边缘凸起顶端、基体平面与织构内壁的拐点以及织构内壁上的凸点位置。有边缘凸起正弦织构的凝固熔滴由中间向两侧逐渐变薄，熔滴在无边缘凸起织构外部呈规则的圆盘状，凹坑织构底部存在“空腔”特征。涂层截面形貌分析发现，有边缘凸起的织构表面的涂层形貌较优，凹坑织构涂层含有较多缺陷，形貌最差。结论 镍基涂层与织构化表面为机械结合。相比凹坑织构，正弦和直线织构更有利于提高涂层的质量。织构边缘凸起的存在对提高喷涂质量也是有利的。

The work aims to study the spreading and solidification characteristics of plasma spraying droplet in surface textures, and to provide theoretical assistance for understanding the influence of surface texturing on the bonding mechanism of plasma sprayed coating and then improving the bond strength of the coating. Numerical models of droplet filling micro textures during plasma spraying were established by using Flow 3D to analyze the temperature field and spreading characteristics. The temperature field and spreading law of droplet filling sinusoidal texture were studied. The effects of texture bulges and shapes on the above factors were compared. Simultaneously, the effects of different textures on coating microstructure were analyzed based on the plasma spraying experiment on laser textured surfaces. It was found that the heat dissipation rate of the texture without bulges was about 0.7 μs faster than that with bulges. The dimple texture had the minimum dissipation rate, and its maximum temperature is still 44.7 K higher than the droplet liquidus (1728.4 K) at the end of the calculation. The highest temperature of the substrate was about 1680.5 K, which is mainly at the top of the bulges, the inflection point between the substrate plane and the texture wall, and the convex point on the texture wall. The solidified droplet in the sinusoidal texture with bulges gradually become thinner from the middle to both sides, the droplet had a regular disc shape outside the texture without bulges, and there was a “cavity” feature at the bottom of the dimple texture. The cross-section morphology analysis of the coatings showed that the coating on the textured surface with bulges had better morphology, while the coating on the dimple textured surface had more defects and the morphology was the worst. Thus, the Ni-based coating is mechanically bonded to the textured surface. Compared with the dimple texture, the sinusoidal and groove textures are more conducive to the improvement of coating quality, and the existence of texture bulges is also beneficial to the spraying quality.