Modeling and Simulation of the Microstructure Evolution of the Gas-atomized Alloy Droplets during Spray Forming

In order to understand the solidification process of an atomized droplet and predict the fraction solidification of droplets with flight distance during spray forming, a numerical model based on the population dynamics approach is developed to describe the microstructure evolution under the common action of the nucleation and growth of grains. The model is coupled with droplets heat transfer controlling equations and solved for AI-4.5 wt pct Cu alloy. It is demonstrated that the numerical results describe the solidification process well.

Shape-predicted model of spray forming rod under scanning atomization

A model for simulating the spray forming process with scanning atomizer was developed.Models for the scanning atomization and the deposition processes were coupled together in order to obtain a new description of the spray forming process.The model,which is able to predict the shape of a spray-formed billet prepared with scanning atomizer,was established after analyzing the changes in droplet size and density distribution along the r-axis in the spray cone in scanning atomization.The effects of the two kinds of atomization were compared,showing that the scanning atomization is good for deposition.

The numerical simulation of the movements and thermal states of atomized metal droplets in the spray forming process

Numerical simulation was performed in an atomizing chamber to investigate the movements and thermal states of the atomized metal droplets in the spray forming process. The velocity, temperature and solid fractions of metal droplets with different diameters and under different atomizing pressures were investigated. The results indicate that a higher atomizing pressure results in the increased flying velocity of the metal droplets and a decrease in the cone-shaped angle formed by their flight paths. Synchronously, the cooling of the metal droplets is accelerated and the time of the complete solidification process is shortened. Under the same atomization pressure, large metal droplets have a lower flying speed and a lower rate of temperature decrease in the atomizing chamber than small metal droplets. In addition, metal droplets flying along the edge of the atomizing region cool faster than those flying in the core region.

Effects of different nozzle materials on atomization results via CFD simulation

Spray drying,as a crucial operation in industrial production,converts solution to fine particle.The spray moiety directly affects the final particle morphology,size and distribution.Compared with the experimental method,computational fluid dynamics(CFD)modeling is a powerful and convenient tool for simulating the spray process.Based on the verified CFD model,different materials of atomizer were simulated to investigate the effect on droplet size and distribution in this work.The modeling result proved that the droplet size and distribution were influenced by the resistance coefficient of materials,wherein the Reynolds number could change the effect of roughness along with the change of mass flow rate on spray process.The results in this work have implication for controlling droplet size through developing new spray nozzle with different materials or surface coating.

Metal Spray Forming Process Examined Using Mathematical Model

The metal spray forming process was examined using the mathematical model simulation by Baosteel＇s test and developed facilities.The mathematical model comprised of the probability and statistical analysis of the droplet mass behavior and predicted the shape and temperature distribution of the billet during the spray forming process.

气体雾化与喷射成形中雾化过程的数学模型

应用波理论描述了金属融体气体雾化与喷射成形中初次雾化阶段的破碎过程,导出了最不稳定的波数方程。结合波峰剥离模型,提出了融滴尺寸预测的数学模型,并在计算机上进行了数值模拟。探讨了雾化参数对破碎过程及融滴尺寸的影响,结果表明:在气流速度大于100m/s的情况下,用表面波理论模拟金属融体初次雾化阶段的破碎过程是合理的;从融滴尺寸角度,选用N2气作雾化气体比较合适;表面张力是影响雾化过程的一个重要参数,表面张力越小,雾化越易进行,破碎后的融滴尺寸越小。

喷射成形Al-Zn合金凝固过程模拟Ⅰ——单个液滴凝固行为

应用群体动力学方法,模拟分析了雾化条件下Al-12Zn合金液滴凝固行为和气体初始速度、熔炼温度等参数对单个液滴凝固过程的影响。结果表明,液滴凝固过程可以分为液体冷却、形核和再辉、晶粒长大和共晶凝固、固体冷却5个阶段;对于给定尺寸的液滴,提高气体初始速度或提高熔炼温度,在相同飞行距离时的固相率减少。