An integrated numerical model for the prediction of Gaussian and billet shapes

Separate models for the atomisation and the deposition stages were recently integrated by the authors to form a unified model describing the entire spray-forming process. In the present paper, the focus is on describing the shape of the deposited material during the spray-forming process, obtained by this model. After a short review of the models and their coupling, the important factors which influence the resulting shape, i.e. Gaussian or billet, are addressed. The key parameters, which are utilized to predict the geometry and dimension of the deposited material, are the sticking efficiency and the shading effect for Gaussian and billet shape, respectively. From the obtained results, the effect of these parameters on the final shape is illustrated.