Three-dimensional simulation of liquid metal spray deposition onto arbitrary surfaces

摘要

In this paper, we present the results of three-dimensional modelling of liquid metal spraying onto arbitrary surfaces. The model is developed in order to simulate the net- or near-net-shape manufacturing processes based on droplet deposition. The processes involve metal droplets hitting the substrate, their splashing, deposition and the redeposition of splashed material, and finally solidification, causing the growth of the deposit.Our model includes all the important phenomena, such as droplets' splashing and the redeposition of re-emitted material. The mass flux distribution for all spray sources is modelled by several simple functions, some of them without any arbitrary modelling parameters. Their applicability is checked by running a set of simulations, and comparisons with the experimental results.The shape evolution in time and topological changes of the moving interface are calculated by the level set method.The model can also predict porosity distribution in the deposited material, defined as a continuous function of the spray's parameters. In cases when the initial geometry contains small holes, the model can predict their closing and the formation of voids in the deposit.