Modeling and Simulation of Spray Forming of Clad Deposits with Graded Interface Using Two Scanning Gas Atomizers

A three-dimensional shape model based on a surface coordinate tracking method has been developed for clad deposits with graded interface which are spray formed using two scanning gas atomizers. The calculation of element distributions in the deposits has been incorporated into the shape model. On this basis, the deposit shape and the element distributions in the deposit have been simulated. It shows that the scanning mode of the atomizers and the degree of overlapping of the two sprays play important roles in the spray forming of clad deposits. A concentration gradient of chemical elements in the deposits can be achieved under proper processing conditions. Finally, the modeling and simulation of the spray forming of clad deposits have been validated by experimental investigations.