Solidification progress and heat transfer analysis of gas-atomized alloy droplets during spray forming

In order to predict gas and droplet velocities, droplet temperature, and fractional solidification with flight distance during spray forming, the Newtonian heat transfer formulation has been coupled with the classical heterogeneous nucleation and the specific solidification process. It has been demonstrated that the thermal profile of the droplet in flight is significantly affected by process parameters such as droplet size, initial gas velocity, undercooling, and superheat. With increasing droplet size or initial gas velocity, the onset and completion of solidification are shifted to greater flight distances and the solidification process also extends over a wider range of flight distances. It has been found that the corresponding solid fractions formed during recalesced, segregated, and eutectic solidifications are linearly related to the degree of undercooling and that those solid fractions are insensitive to droplet size, initial gas velocity and superheat.