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Numerical Modeling of Impact and Solidification of a Molten Alloy Droplet on a Substrate

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Advances in Material Forming and Joining

Part of the book series: Topics in Mining, Metallurgy and Materials Engineering ((TMMME))

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Abstract

Most of the studies reported for droplet impact and spreading on a substrate in a thermal spray coating process assume that droplet material solidifies as a pure substance, i.e., phase change occurs at a fixed temperature. The alloy-type behavior of the droplet impact where it solidifies within liquidus and solidus temperature is not well reported. The role of formation of mushy zone and species composition variation during the coating layer formation while using a multi-constituent alloy material is not established. This work investigates the spreading and solidification characteristics of an alloy droplet impacting on a substrate. Two-dimensional axisymmetric model has been used to simulate the transient flow and alloy solidification dynamics during the droplet impingement process. Volume of fluid (VOF) surface tracking method coupled with the alloy solidification model within a one-domain continuum formulation is developed to describe the transport phenomena during the droplet impact, spreading, and solidification of an alloy droplet on a flat substrate. Using the model, the characteristics of alloy solidification in coating formation are highlighted.

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Abbreviations

c :

Specific heat capacity (m2 s−2 K−1)

C :

Solute concentration (kg kg−1)

D :

Solute mass diffusivity (m2 s−1)

D o :

Initial droplet diameter (mm)

f l :

Weight fraction of liquid (kg kg−1)

f s :

Weight fraction of solid (kg kg−1)

F :

Volume of fluid function

F vol :

Continuum surface tension force source term (N m−3)

\(\vec{g}_{r}\) :

Acceleration due to gravity vector (m s−2)

k :

Thermal conductivity (W m−1 K−1)

k p :

Equilibrium partition coefficient

K :

Permeability of mushy zone (m2)

L :

Latent heat of fusion (J kg−1)

m L :

Liquidus slope (°C wt%−1)

p :

Pressure (N m−2)

t :

Time (s)

T :

Temperature (K)

T m :

Melting point of pure substance (K)

\(\vec{u}\) :

Continuum velocity vector (m s−1)

U 0 :

Initial droplet velocity (m s−1)

ρ :

Density (kg m−3)

μ :

Dynamic viscosity (kg m−1 s−1)

d:

Droplet

subs:

Substrate

air:

Air

alloy:

Alloy

eff:

Effective

l:

Liquid

s:

Solid

0:

Initial

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, 208016, India

    Rajesh Kumar Shukla, Sateesh Kumar Yadav, Mihir Hemant Shete & Arvind Kumar

Authors
  1. Rajesh Kumar Shukla
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  2. Sateesh Kumar Yadav
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  3. Mihir Hemant Shete
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  4. Arvind Kumar
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Corresponding author

Correspondence to Arvind Kumar .

Editor information

Editors and Affiliations

  1. Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam, India

    R. Ganesh Narayanan

  2. Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam, India

    Uday Shanker Dixit

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Shukla, R.K., Yadav, S.K., Shete, M.H., Kumar, A. (2015). Numerical Modeling of Impact and Solidification of a Molten Alloy Droplet on a Substrate. In: Narayanan, R., Dixit, U. (eds) Advances in Material Forming and Joining. Topics in Mining, Metallurgy and Materials Engineering. Springer, New Delhi. https://doi.org/10.1007/978-81-322-2355-9_16

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  • DOI: https://doi.org/10.1007/978-81-322-2355-9_16

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  • Publisher Name: Springer, New Delhi

  • Print ISBN: 978-81-322-2354-2

  • Online ISBN: 978-81-322-2355-9

  • eBook Packages: EngineeringEngineering (R0)

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