| Abstract: |
In this paper, a numerical study is performed to investigate the effects of Melting and deformation of solid substrate by impinging of molten droplet in thermal spray process using the Volume-of-Fluid (VOF) method. Substrate melting is a phenomenon caused by the plasma arc spray during impacting and solidification of a molten metal. The Navier-Stokes equations along with the energy equation including phase change are solved using a 2D/axisymmetric mesh with commercial fluent code. The VOF method is used to track the free surface of molten particles, and an enthalpy-porosity formulation is used to model melting and solidification. For a normal impact of molybdenum particle in the order of 30 ¼m in diameter and 150 m/s in impact velocity, the final splat had a single cavity inside due to high speed and temperature. For this case with the scales of a typical thermal spray process. The surface melting depth and maximum height of Splat increase directly depends on the substrate thickness, also maximum temperature and splat flattening ratio directly depends on substrate temperature.
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