Modelling the shape and thermal dynamics of Ni superalloy rings during spray forming. Part 2: Thermal modelling – Heat flow and solidification Original Research Article

In Part 1 of this paper, a model was described to simulate the dynamic shape evolution of Ni superalloy rings during spray forming, concentrating on the effects of droplet splashing and redeposition. In this part, a companion model is presented that simulates the heat flow and solidification of the Ni superalloy rings during spray forming. In this model, generic algorithms of (1) coupling of droplet mass and enthalpy at a deposition surface, and (2) data mapping between time-evolving computational domains were developed and implemented. The effects of (1) droplet redeposition, and (2) changes in the convective heat transfer coefficients and their distributions on the resulting ring preform heat flow and solidification were studied; and simulations were again compared with experiments. The model was applied to investigate the effects of key processing parameters on the internal heat flow and solidification of large diameter IN718 alloy rings.