Thermal simulation of spray forming process

In this contribution specific modules for the derivation of an integrated simulation model for the spray forming process are presented. For this aim, at first the interface between the spray and the growing deposit is highlighted. At this stage the particle mass from the spray is compacted on the top surface of the deposit. Beginning with an analysis of solidification and heat transfer of individual particles within the spray, suitable averaging methods for the description of the overall thermal energy transfer into the deposit are derived. In the next step, the material cooling within the deposit is related to the remaining grain size of the sprayed product, based on simulated model results from the spray simulation. Based on these modules, finally the successive thermal behaviour of a material element from the tundish via the spray into the deposit is investigated for different process conditions.