An essential feature of the spray forming process for the production of near net shaped metal products is a suitable composition of the spray cone prior to impingement onto the substrate or deposit. Excellent product qualities and homogeneities need a mixture of particles in different stages of their individual solidification. Modelling of phase change behaviour of metal melts is an important part of an overall thermal modelling of the process. Control of the solidification process is one of the key issues in spray forming research. The thermal history of a metal element from superheating (in advance of the atomization process) via solidification and cooling to room temperature has significant influence on the resulting material properties of the product. Dependent on the alloy composition, individual solidification models must be derived.
This contribution describes the droplet solidification in flight in the spray cone and further on in the resulting deposit during spray forming for a steel alloy. For the simulation of the spray cone behaviour, a multiphase flow model is established including momentum and thermal coupling. The description of the transient thermal conditions in the sprayed deposit, including necessary boundary conditions, is derived in a general coordinate based heat conduction algorithm.