Modeling and simulation of the microstructure evolution of the gas-atomized alloy droplets during spray forming

In order to understand the solidification process of an atomized droplet and predict the fraction solidification of droplets with flight distance during spray forming, a numerical model based on the population dynamics approach is developed to describe the microstructure evolution under the common action of the nucleation and growth of grains. The model is coupled with droplets heat transfer controlling equations and solved for Al-4.5 wt pct Cu alloy. It is demonstrated that the numerical results describe the solidification process well.