This report is made as a study to optimize upon a zinc arc spray to give a better coating quality on a substrate profile. The study was made using a CAD model of an emulated production process including a housing for the spraying process, a substrate profile that the zinc is sprayed upon, and an air flow that emulates a ventilation system.

ANSYS Fluent is used as the CFD modeling tool, with a particle size distribution constructed as a Rosin-Rammler size distribution and a particle release radius of 0.3 mm. The parameters that were investigated was the spray angle onto the substrate profile and the spray distance to the profile.

From the investigation of the effect of changing the spray angle, it was found that the optimal angle would be a spray angle of 60 degree as this resulted in the best coverage of the substrate profile.

With the investigation of the effect of changing the spray distance, it was determined that a spray distance of 140 resulted in the most evenly distributed coating coverage of the substrate profile.