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A 3D numerical study on impact-freezing of Nickel drops in thermal spraying conditions

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Abstract

Modeling drop impact in 3D in thermal spraying conditions poses a great challenge, since it requires first of all an accurate interface tracking model and an efficient numerical scheme to solve the governing equations. This paper thus put forward an integrated model, in the framework of the conservative level set equation, to simulate drop impact in real thermal spraying conditions. The model couples the conservative level set equation with the Navier–Stokes equation and is discretized using the finite difference method on a half-staggered grid. The model was validated against experimental data, showing reasonable agreement. Then it was applied to real impact in thermal spraying conditions. Nickel drop impact with solidification was simulated first. Subsequently, effects of contact angle, thermal contact resistance, and substrate materials, were examined. It shows that lower contact angle does not lead to larger contact area, since solidification commences faster around the contact line, thereby pinning its movement, and that thermal contact resistance exerts a huge impact on final splat shape. The smaller the contact resistance, the more violent the splash.

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Acknowledgements

This research is supported by the Natural Science Foundation of the Jiangsu Higher Education Institutions of China (Grant No. 21KJB460034).

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Authors and Affiliations

  1. School of Mathematics and Statistics, Yancheng Teachers University, Yancheng, 224002, People’s Republic of China

    Mingguang Shen

  2. Department of Mechanical Engineering, University of Michigan, Dearborn, MI, 48128, USA

    Ben Q. Li

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Shen, M., Li, B.Q. A 3D numerical study on impact-freezing of Nickel drops in thermal spraying conditions. Appl. Phys. A 129, 509 (2023). https://doi.org/10.1007/s00339-023-06781-0

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