Analysis of deposit growth in spray forming with multiple atomizers

In spray forming, multiple atomizers may be used simultaneously to increase the throughput and to spray large size billets. In addition, the advantage of the use of multiple sprays is better control of the distribution of the incoming mass and enthalpy fluxes on the deposit surface. By this, the thermal condition in the top layer of the billet is controlled to ensure steady-state growth and cooling of the deposit. The interaction of two overlapping sprays is described in this paper. The mass flux and the enthalpy distribution have been experimentally investigated for different spray conditions and overlapping angles of the two sprays. Starting from a geometric model, a three-dimensional simulation of the preform geometry and incoming enthalpy flux on the top layer of the deposit has been conducted. The most relevant process parameters and physical properties are taken into account in this model. The model results are in good agreement with experimental preform shapes.