Three modules describing metal behaviour during sequential stages of the spray-forming process are coupled in this contribution to provide an integrated thermal simulation of the process. These sub-models describe the melt delivery to the atomizer (tundish), the spray, and the consolidation. Process properties of particular concern in these models are the melt cooling rates and residence times in the various stages of the spray-forming process, and the interface conditions between the spray and the deposit, where the sprayed material impinges onto the substrate or surface of the deposit. The input parameters for each successive sub-model are delivered by the preceding module.
The tundish module describes the heat and melt flow behaviour in the tundish, and the spray simulation module defines the multi-phase flow in the spray by considering properties of individual particles. The thermal energy inputs for the deposit module are derived from the spray model by specific averaging procedures. The solidification and cooling parameters of the deposit are then derived in the consolidation module.
These sequential modules describe the thermal behaviour of a melt element throughout all the successive stages in the spray-forming process, from atomization in the liquid state via the spray stage and compaction to the final cooling (to room temperature).
Using the coupled model, main process parameters are varied and their influence is discussed.