Numerical Investigation of Substrate Melting and Deformation During Thermal Spray Coating by SPH Method

Abstract

The fluid-solid coupling model is developed to simulate substrate melting and deformation during molten droplet impact. In this model, the liquid and solid parts of splat and substrate are governed by the SPH formulations of the Navier-Stokes equations and the conservation equations of continuum mechanics, respectively. This is the first time that the fluid-solid coupling by the SPH method is applied to simulation of the interaction between droplet and substrate during thermal spray coating. The simulation results on formation of the crater are presented to study the Ni droplet impacting onto the Sn substrate, and Mo droplet impacting onto the Steel, Al, and Brass substrates, respectively. It is found that the initial temperatures and thermal properties of droplet and substrate have great effects on the substrate melting and the morphologies of the splat and the substrate.

Smoothed Particle Hydrodynamics (SPH): an Overview and Recent Developments

“…• multi-phase flows [119,[166][167][168][169][170][171][172][173][174], • coastal hydrodynamics including water wave impact, dam break, sloshing and overtopping [112,, • environmental and geophysical flows including flood and river dynamics, landslide, flow in fractures and porous media, seepage, soil mechanics and mudflow [117,, • heat and/or mass conduction [53,[222][223][224][225][226][227], • ice and cohesive grains [228][229][230][231][232][233][234], • microfluidics and/or micro drop dynamics [123,152,169,[235][236][237][238][239][240][241][242][243][244][245][246], • high explosive detonation and explosion [55,125,143,[247][248]…”

“…Li et al proposed an SPH model for simulating droplet collision and coalescence [367]. Zhang et al developed an SPH model for free surface and solidification problems, which is also applicable to microfluidics and micro drop dynamics such as droplet spreading, splashing and solidification, substrate melting and deformation [243][244][245]. A revised surface tension model was developed for macro-scale particle methods including SPH by Zhou et al [246].…”

Simulation of surface tension in 2D and 3D with smoothed particle hydrodynamics method

“…Meshless methods such as SPH method [7][8][9] has been applied to simulate the fluid flow with free surface. Nugent and Posch [10] first developed a SPH model for surface tension.…”

New smoothed particle hydrodynamics (SPH) formulation for modeling heat conduction with solidification and melting

“…Cleary et al [14,15] focused on the explicit inclusion of latent heat after solving the enthalpy form of the heat conduction equation. This method has been used to model casting [16] and solidification of molten metal drops impacting a surface [17,18,19]. Monaghan et al [20] modelled the solidification of pure and binary alloys, where phase change was simulated by removing liquid particles and transferring their mass to a stationary grid of solid particles.…”