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Drop impact is common in industrial applications and nature. As in the 3D printing, the drops squeezed out of the nozzle do not have to take on a spherical shape. This paper delves into the role of drop shape in drop impact with solidification under the 3D printing conditions. To track the rapidly evolving liquid-gas interface, the Cahn-Hilliard-based phase field method is employed. The solid-liquid interface is tracked by the liquid fraction. The model is discretized using an explicit finite difference scheme on a half-staggered grid. The code was written in FORTRAN and enhanced with the OpenMP technique. After being validated against experimental data, the model was applied to various cases. Moreover, the paper took into account a number of factors influencing drop impact and solidification dynamics, such as aspect ratio, contact angle, and thermal contact resistance. It was found that the aspect ratio exerts little effect on drop profile for the cases under consideration when solidification is on, but that the contact angle could drastically reduce freezing time, converting the convex solidfication pattern to a concave one. [ABSTRACT FROM AUTHOR]

In thermal spraying, molten YSZ (Yttria Stabilized Zirconia) drop impact is crucial to the understanding of formation of splats and hence coatings. However, existing studies hardly cast attention to the possible rebounding dynamics when successive molten YSZ drops impinge onto newly solidified splats whose temperature is still high so that freezing may be delayed. This work uses a newly developed numerical model based on the conservative level set method to probe into the rebounding dynamics of YSZ drops in practical thermal spraying conditions. The free-energy-based surface tension model in the phase field method was introduced to avoid the computing of curvature, which is however necessary in the continuum surface tension model. The projection method was invoked to solve the Navier–Stokes equations. The model was validated against an experiment of drop impact with rebounding, showing reasonable agreement. Moreover, the model was applied to both dense and hollow YSZ drop impact, with the details of fluid flow being analyzed. The maximum spread factor was found in agreement with existing scaling laws. [ABSTRACT FROM AUTHOR]

Drop impact dynamics with solidification has been a hot topic of research recently. However, numerical studies to that end mainly concentrate on spherical drops, paying less attention to non-spherical ones that are ubiquitous in industrial applications like additive manufacturing and plasma spraying. Therefore, a phase field model accelerated with the shared-memory parallelism OpenMP is proposed to simulate the impact of a non-spherical heavy metal droplet in actual additive manufacturing conditions. The tracking of the gas–liquid interface is realized by the finite difference solution of the Navier–Stokes equation and the Cahn–Hilliard equation. We use the liquid fraction defined all over the computational domain to distinguish between solid and fluid. The model was then employed to predict the impact and freezing dynamics of non-spherical droplets, with the focus on the effects of the aspect ratio, of the contact angle, and of the phase field mobility. It shows that the established model could well capture the axis switching process, that rebounding accompanying the axis switching process could be hindered by solidification, and that larger phase field mobility could smooth drop profile, rendering it round in the axis switching process. [ABSTRACT FROM AUTHOR]

Air entrapment in drop impact onto solid surfaces has riveted the attention of the scientific community since it could drastically influence heat rate and splat porosity in additive manufacturing or thermal spraying processes. Due to the limitations of experimental methods, numerical methods have been gaining popularity in probing into air entrapment dynamics. To that end, this paper developed a paralleled phase field model. The model couples the Navier–Stokes equations with the Cahn–Hilliard equation to capture the liquid–gas interface, and adopts the liquid fraction, defined all over the computational domain, to distinguish between solid and liquid. The model is discretized using a finite difference method on a half-staggered grid. The model was first compared with experimental data, achieving reasonable agreement. Afterward, it was applied to a couple of cases. The air entrapment process was captured entirely and the interaction between solidification and air entrapment was also given. It shows that under the parameters studied here air entrapment may occur twice, one in the impacting center in the form of a bubble and the other in the form of a bubble ring. Besides, the effect of phase field mobility on air entrapment was examined as well. [ABSTRACT FROM AUTHOR]

A comprehensive numerical model has been developed, which is capable of predicting the spreading of a high-speed yttria-stabilized zirconia (YSZ) droplet with solidification microstructure formation under a horizontal electric field in plasma spraying processes. The numerical model entails the explicit finite difference solution of the Navier–Stokes equations and the energy balance equation, coupled with the Cahn–Hilliard equation to track the liquid–gas two-phase interface and with a phase field model for solidification microstructure formation involving polycrystalline growth. The electric force is added as a source term in the Navier–Stokes equations, and the fluids are assumed to be perfect dielectrics. The in-house code is written in Fortran and run in parallel. The results reveal that the retracting process could be completely inhibited using a horizontal electric field and that solidification time is greatly reduced. A new mechanism to suppress droplet breakup/splash could be realized, featuring reduction of the rising angle the spreading front makes with a substrate. All the cases show columnar grains within a splat. Besides, the model is validated against experimental results, with gratifying agreement achieved. [ABSTRACT FROM AUTHOR]

Modeling drop impact in 3D in thermal spraying conditions poses a great challenge, since it requires first of all an accurate interface tracking model and an efficient numerical scheme to solve the governing equations. This paper thus put forward an integrated model, in the framework of the conservative level set equation, to simulate drop impact in real thermal spraying conditions. The model couples the conservative level set equation with the Navier–Stokes equation and is discretized using the finite difference method on a half-staggered grid. The model was validated against experimental data, showing reasonable agreement. Then it was applied to real impact in thermal spraying conditions. Nickel drop impact with solidification was simulated first. Subsequently, effects of contact angle, thermal contact resistance, and substrate materials, were examined. It shows that lower contact angle does not lead to larger contact area, since solidification commences faster around the contact line, thereby pinning its movement, and that thermal contact resistance exerts a huge impact on final splat shape. The smaller the contact resistance, the more violent the splash. [ABSTRACT FROM AUTHOR]

In plasma spraying, copious heterogeneous nucleation starts when a molten ceramic droplet spreads on a cold surface under rapid cooling. Some nuclei will survive and grow, eventually forming a splat of grains of distinct crystalline orientations. This paper aims to predict the dynamic process of yttria-stabilized zirconia (YSZ) droplet impact with solidification microstructure formation under various plasma spray conditions. A diffuse interface model was developed to track the evolving liquid–gas and solid–liquid interfaces. Continuously dense YSZ droplet impacts with different impacting angles were conducted, along with a hollow droplet impact. Results reveal that competitive growth among crystals is limited in the planar solidification, and that columnar structure dominates all the tests performed owing to a large thermodynamic driving force, and that given the rapid spreading of YSZ droplets along a solid surface, solidification may be safely assumed to take place mostly after spreading. Besides, typical crystal growth velocities are around 1 m/s, and local equilibrium can be assumed in the bulk. [ABSTRACT FROM AUTHOR]