Modeling of solidification and velocity of atomized molten droplet during atomization and spray forming

The solidification behaviors and velocity of atomized droplets during flight is formulated by a mathematical model, in which the concept of transient nucleation is applied. During the flight, the droplet velocity shows a maximum, followed by an inflection phenomenon. The velocity of large droplet is lower than that of small droplet at shorter flight distance, and higher than that of small droplet at longer flight distance. The effect of the gas flow pattern is more significant at longer flight distance than at shorter flight distance At a given flight distance, large droplet has higher temperature than small droplets prior to nucleation. Large droplet has higher nucleation temperature than small droplet, Medium size droplet flies over the shortest flight distance before the nucleation starts. At the end of recalescence, large droplet has less solid fraction than small droplet has.