Numerical Simulation of Droplet Impact on Patterned Surfaces |
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Authors: | HB Parizi L Rosenzweig J Mostaghimi S Chandra T Coyle H Salimi L Pershin A McDonald C Moreau |
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Affiliation: | (1) Simulent Inc., 203 College Street, Suite 302, M5T 1P9 Toronto, ON, Canada;(2) GE Global Research, New York, USA;(3) University of Toronto, Toronto, ON, Canada;(4) National Research Council Canada, Boucherville, QC, Canada |
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Abstract: | This work presents numerical simulation results for molten nickel and zirconia (YZS) droplets impacting on different microscale-patterned
surfaces of silicon. The numerical simulation clearly showed the effect of surface roughness and solidification on the shape
of the final splat, as well as the pore creation beneath the sprayed material. Simulations were performed using computational
fluid dynamic software, SimDrop. The code uses a three-dimensional finite-difference algorithm solving the full Navier-Stokes
equation, including heat transfer and phase change. A volume of fluid (VOF) tracking algorithm is used to track the droplet-free
surface. Thermal contact resistance at the droplet-substrate interface is also included in the model. Specific attention is
paid to the simulation of droplet impact under plasma spraying conditions. Droplet sizes ranged from 15 to 60 microns with
initial velocities of 70-250 m/s. Substrate surfaces were patterned with regular arrays of cubes 1-3 μm high, spaced either
1 μm or 5 μm from each other. Different splat morphologies produced by simulations are compared with those obtained from the
experiment conducted under the same impact and surface conditions.
This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been
expanded from the original presentation. It is simultaneously published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 14-16, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain
Montavon, Ed., ASM International, Materials Park, OH, 2007. |
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Keywords: | droplet impact numerical simulation patterned surface solidification thermal spray coating |
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