Modeling of Porosity during Spray Forming: Part I. Effects of Processing Parameters

摘要

It this article ,a porosity model is developed basedon particle packing theory ,fluid mechanics ,and particle thermaland dynamic behavior during spray forming .According to thismodel ,the amount of porosity in as-deposited materials can beestimated on the basis of the average fraction of solid in theincident spray and the solid particle packing density .A porositycoefficient Ф is introduced .By using this model ,the effects ofdeposition distance ,atomization gas pressure ,melt flow rate ,andmelt superheat on porosity are investigated .The amount ofporosity demonstrated distinct V-shaped variations with theprocessing parameters .Finally ,the optimal processingparameters for achieving low porosity are discussed on the basisof the calculated results.