Abstract
In spray deposition, a stream of molten metal is atomised with an inert gas to form a spray of molten droplets; these are then accelerated towards a substrate where they impinge and consolidate. Near-net shape products can be manufactured by technologies involving solidification and droplet consolidation. In order to maximise the metallurgical benefits of gas atomisation and deposition, a thorough characterisation of momentum and heat transfer is required in the gas atomised spray.
This paper describes a mathematical model to predict thermal history and solidification behaviour of atomised droplets of aluminium, copper and nickel during flight. The model estimates nucleation temperature, nucleation position and the extent of droplet solidification during flight. The influence of the type of metal, atomising gas, deposition distance, different gas velocity correlations and droplet size on solidification characteristics are discussed.
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