J. Mi, P. S. Grant, University of Oxford, Oxford, United Kingdom
A multiphysics numerical model has been developed at Department of Materials, University of Oxford to simulate the net-shape spray forming process. The model consisted of four sub-models: (1) a droplet deposition model simulating droplet deposition, splashing and re-deposition behavior and the resulting preform dynamic shape; (2) a preform heat flow model simulating the preform internal heat flow and solidification behavior; (3) a porosity model simulating the porosity distribution inside the spray formed preform; (4) a thermal stress model simulating the thermal stress evolution during spray forming and the subsequent cooling stage. The model has been validated against experiments of the spray forming of profiled IN718 Ni superalloy rings. The modelled preform shape, surface temperature, microporosity distribution and thermal stresses showed good agreement with experimental measurements. The model has been proven as a powerful tool for the optimisation of the net-shape spray forming process.
Summary: A multiphysics numerical model has been developed at Department of Materials, University of Oxford to simulate the net-shape spray forming process. The model consisted of four sub-models: (1) a droplet deposition model simulating droplet deposition, splashing and re-deposition behavior and the resulting preform dynamic shape; (2) a preform heat flow model simulating the preform internal heat flow and solidification behavior; (3) a porosity model simulating the porosity distribution inside the spray formed preform; (4) a thermal stress model simulating the thermal stress evolution during spray forming and the subsequent cooling stage. The model has been validated against experiments of the spray forming of profiled IN718 Ni superalloy rings. The modelled preform shape, surface temperature, microporosity distribution and thermal stresses showed good agreement with experimental measurements. The model has been proven as a powerful tool for the optimisation of the net-shape spray forming process.
