The Numerical Simulation Of Arc Spray Process

The arc spray is one of the thermal spray technologies. In the arc spray, the droplet velocity and temperature are very important for the coat quality. There are so many difficulties when using physical experiments, while currently for this problem numerical simulation is an important method.Based on the two-phase flow model and by using the ANSYS/CFD multiple species transport program, the droplet velocity and temperature in the arc spray were investigated detailed, and then by using the explicit FEA software LS_DYNA we analyzed the droplet flattening after impacting on the flat substrate, and in all the flattening process, the ALE method was employed always.By altering the material and the air pressure, the differences of the droplet behavior of the Al, Zn and stainless steel(1Cr18Ni9Ti) were discussed, and the effect of the air pressure on the droplet velocity, temperature and flattening process were also investigated.The simulation results indicated, for the same material, the droplet velocity, temperature and the compressed rate would be improved by increasing the pressure;and the two-phase flow viscosity μ_mix was an important factor for the droplet velocity distribution.The physical experiment was also employed in this article to validate the result of the temperature simulation.