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A mathematical model of the spray deposition process

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Abstract

Spray deposition is a recently developed atomization process desigted to produce high density, bulk metal shapes directly from the melt. The process consists of two basic steps: first, a molten metal stream is atomized using a gas; the spray thus produced is then collected onto a suitably designed substrate. In this paper a mathematical model for the analysis of heat transfer during SD is described. The model is in two parts: the first part calculates the thermal histories of atomized droplets in flight, whereas the second part computes the transient temperature profiles inside the growing preform. More specifically, the mathematical model estimates droplet size distribution, temperatures, fractional solidification and microstructures of the atomized droplets in the spray, and the temperature field and microstructure of the resulting deposit. In contrast atively low (1 to 10 °C/second). The results also indicate that a small fraction of liquid mixed with solid exists at the top of the growing preform during deposition. The tiny pools of liquid may play a role in the formation of the characteristic equiaxed grain microstructure of as deposited preforms. The results of the calculations are very sensitive to the value of the enthalpy of the impinging spray. Therefore, the production of good quality deposits requires accurate control of the heat fluxes during deposition.

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Authors and Affiliations

  1. Department of Metallurgy, The Hartford Graduate Center, 275 Windsor Street, 06120, Hartford, CT

    E. Gutierrez-Miravete (Curriculum Chair and Assistant Professor)

  2. Research Affiliate, Department of Materials Science and Engineering, Massachusetts Institute of Technology, 02139, Cambridge, MA

    E. Gutierrez-Miravete (Curriculum Chair and Assistant Professor)

  3. Department of Mechanical Engineering, University of California at Irvine, 92717, Irvine, CA

    E. J. Lavernia (Assistant Professor)

  4. Department of Materials Science and Engineering, Massachusetts Institute of Technology, 02139, Cambridge, MA

    G. M. Trapaga (Graduate Student), J. Szekely (Professor of Materials Engineering) & N. J. Grant (Professor of Metallurgy)

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  1. E. Gutierrez-Miravete
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  2. E. J. Lavernia
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  3. G. M. Trapaga
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  4. J. Szekely
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  5. N. J. Grant
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E.J. Lavernia formerly, Research Associate, Department of Materials Science and Engineering, Massachusetts Institute of Technology, Cambridge, MA, 02139

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Gutierrez-Miravete, E., Lavernia, E.J., Trapaga, G.M. et al. A mathematical model of the spray deposition process. Metall Trans A 20, 71–85 (1989). https://doi.org/10.1007/BF02647495

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