An integrated model for interaction between melt flow and non-equilibrium solidification in thermal spraying

In this paper, a micro/macro-integrated model based on the VOF scheme is presented that accounts for free surface movement, thermal contact resistance, and fluid instability. A sub-model is developed to include the non-equilibrium solidification phenomena at the solid/liquid interface. The melt flow is incorporated into the microscopic model through prescribing a velocity profile that is obtained from the interpolation of melt velocities on the macroscopic grids near the interface. To improve the efficiency of the integration between the melt flow and the microscopic model, a relational database is developed and applied to the integrated micro/macro model. Three velocity profiles, e.g., linear, parabolic, and cubic velocity profiles, are considered and the results are compared with those obtained from the diffusion model.