Numerical simulation of temperature distribution and solidification behaviour during spray forming

A mathematical, two‐dimensional model for the analysis of the temperature and solidification behaviour in the substrate and deposit for the spray forming process of metals has been developed. Due to the irregular shape of the growing deposit, which changes with spraying time, a grid transformation method was successfully developed for the calculation of the temperature distribution and solidification front in the growing deposit. The influence of process parameters, i.e. thermal conditions of the metal spray at impact, heat transfer coefficient at the surface of the deposit and geometrical parameters, are qualitatively and quantitatively discussed.