Numerical Simulation of High Speed Molten Nickel Droplet Impacting on the Stainless Steel Substrate

doi:10.12422/j.issn.1672-6952.2025.02.009

Abstract

Abstract:

The solidification and splash phenomena of Ni during plasma spray deposition were simulated by VOF model. The Navier?Stokes equations are solved in combination with the volume?of?fluid technique to track the free surface of the particles. In addition, the heat transfer including phase change is modeled using the enthalpy method. The coating formation process of nickel droplets at high speed was simulated by setting three different experimental conditions. The formation mechanism of nickel coating was analyzed deeply. During the spraying process of different speeds, the diffusion coefficient of higher droplet speed is greater than that of slower speed and there will be splash. In the case of different substrate temperatures, the higher the substrate temperature, the farther the molten particle tiling distance is. In addition, the diameter of the molten droplet is changed. Under the same other simulation conditions, the larger the particle diameter, the larger the spread distance, but it is not linearly related, and the larger the particle, the greater the thickness of the solidified sheet.

Key words: VOF model, Plasma spraying, Solidification, Nickel, Coatings

摘要：

采用VOF模型模拟了熔融镍液滴在等离子喷涂沉积过程中的凝固和飞溅现象，并通过动量方程与流体体积法相结合的方法分析了颗粒的自由表面；利用焓法对包含相变的热传递过程进行了建模；通过设定三组不同的实验条件，模拟镍液滴形成涂层的过程，深入分析了镍涂层的形成机理。结果表明，液滴的撞击速度越大，其扩展系数越大，并且在喷涂过程中会产生飞溅现象；基板温度越高，液滴的扩散距离越大；液滴直径越大，扩散距离越大，但并非呈严格的线性关系，并且其凝固形成的薄片越厚。

关键词: VOF模型, 等离子喷涂, 凝固, 镍, 涂层

CLC Number:

TG146

Ao KANG, Nianchu WU. Numerical Simulation of High Speed Molten Nickel Droplet Impacting on the Stainless Steel Substrate[J]. Journal of Liaoning Petrochemical University, 2025, 45(2): 68-75.

康奥, 吴念初. 高速熔融镍液滴撞击不锈钢基板数值模拟[J]. 辽宁石油化工大学学报, 2025, 45(2): 68-75.

Figures/Tables 7

Fig.1 Droplet impact mesh model

Table 1 Physical properties of materials and substrates[26]

参数	数值
参数	镍	不锈钢
密度/（kg·m^－3）	7 500	8 000
热导率/（W·m^－1·K^－1）	80	16
比热容/（J·kg^－1·K^－1）	600	500
黏度/（Pa·s）	0.002	－
表面张力/（N·m^－1）	1.78	－
潜热/（J·g^－1）	297	－
熔点/K	1 732	－

Fig.2 The diffusion of droplets and their temperature distribution nephogram at different impact velocities

Fig.3 The curves of the diffusion coefficients of droplets with different impact velocities changing over time

Fig.4 The diffusion of droplets and their temperature change nephogram at the temperatures of the substrate are different

Fig.5 The curves of the diffusion coefficients of droplets changing with time under different substrate temperatures

Fig.6 The diffusion of droplets and their temperature distribution nephogram at different droplet diameters

References 28

1	IQBAL A， SIDDIQUE S， MAQSOOD M， et al. Comparative analysis on the structure and properties of Iron⁃Based amorphous coating sprayed with the thermal spraying techniques［J］. Coatings， 2020， 10（10）： 1006.
2	SWAIN B， MANTRY S， MOHAPATRA S S， et al. Investigation of tribological behavior of plasma sprayed NiTi coating for aerospace application［J］. Journal of Thermal Spray Technology， 2022， 31（8）： 2342⁃2369.
3	LANZUTTI A， SORDETTI F， MARIN E， et al. The use of thin films as defect sealants to increase the corrosion resistance of thermal spray coatings［J］. Metals， 2023， 13（10）： 1778.
4	JOLLY A， VITRY V， AZAR G T P， et al. Surface defect mitigation of additively manufactured parts using surfactant⁃mediated electroless nickel coatings［J］. Materials， 2024， 17（2）： 406.
5	DARUT G， DIEU S， SCHNURIGER B， et al. State of the art of particle emissions in thermal spraying and other high energy processes based on metal powders［J］. Journal of Cleaner Production， 2021， 303： 126952.
6	JOSHI S. Special issue： Advances in thermal spray technology［J］. Materials， 2020， 13（16）： 3521.
7	KAURA S， SHARMA S， BALA N. Comparison of surface coatings by plasma spray technique and biomimetic deposition on Ti alloy substrate： Morphology， composition， and corrosion resistance property［J］. Protection of Metals and Physical Chemistry of Surfaces， 2019， 55（3）： 583⁃590.
8	孙亚雄，曹凤婷，王铁钢，等. 多功能型防腐涂层的研究现状及进展［J］. 辽宁石油化工大学学报， 2024， 44（5）： 72⁃81.
	SUN Y X， CAO F T， WANG T G， et al. Research progress of multi⁃function anti⁃corrosion coatings［J］. Journal of Liaoning Petrochemical University， 2024， 44（5）： 72⁃81.
9	江利丰，张广伟. 超音速火焰喷涂WC⁃10Co4Cr涂层组织及耐磨耐蚀性研究［J］. 辽宁石油化工大学学报， 2017， 37（2）： 54⁃59.
	JIANG L F， ZHANG G W. Study on the microstructure and wear/corrosion resistance of WC⁃10Co4Cr coating deposited by high velocity oxy⁃fuel［J］. Journal of Liaoning Shihua University， 2017， 37（2）： 54⁃59.
10	GHOLIJANI A， SCHLAWITSCHEK C， GAMBARYAN⁃ROISMAN T， et al. Heat transfer during drop impingement onto a hot wall： The influence of wall superheat， impact velocity， and drop diameter［J］. International Journal of Heat and Mass Transfer， 2020， 153： 119661.
11	SIVASANKAR V S， ETHA S A， HINES D R， et al. Coalescence of microscopic polymeric drops： Effect of drop impact velocities［J］. Langmuir， 2021， 37（45）： 13512⁃13526.
12	LIN M， VO Q， MITRA S， et al. Viscous droplet impingement on soft substrates［J］. Soft Matter， 2022， 18（29）： 5474⁃5482.
13	PASANDIDEH⁃FARD M， QIAO Y M， CHANDRA S， et al. Capillary effects during droplet impact on a solid surface［J］. Physics of Fluids， 1996， 8（3）： 650⁃659.
14	PASANDIDEH⁃FARD M， AZIZ S D， CHANDRA S， et al. Cooling effectiveness of a water drop impinging on a hot surface［J］. International Journal of Heat and Fluid Flow， 2001， 22（2）： 201⁃210.
15	SHAKERI S， CHANDRA S. Splashing of molten tin droplets on a rough steel surface［J］. International Journal of Heat and Mass Transfer， 2002， 45（23）： 4561⁃4575.
16	XUE M X， CHANDRA S， MOSTAGHIMI J. Investigation of splat curling up in thermal spray coatings［J］. Journal of Thermal Spray Technology， 2006， 15（4）： 531⁃536.
17	MCDONALD A， MOREAU C， CHANDRA S. Thermal contact resistance between plasma⁃sprayed particles and flat surfaces［J］. International Journal of Heat and Mass Transfer， 2007， 50（9⁃10）： 1737⁃1749.
18	谢义英，李强. 等离子喷涂8YSZ涂层在铝熔体作用下热冲击行为的数值模拟［J］. 表面技术， 2018， 47（4）： 102⁃108.
	XIE Y Y， LI Q. Numerical simulation of thermal shock behavior of plasma sprayed 8YSZ thermal barrier coatings subjected to molten aluminum［J］. Surface Technology， 2018， 47（4）： 102⁃108.
19	SHEN M G， LI B Q， BAI Y. Numerical modeling of YSZ droplet impact/spreading with solidification microstructure formation in plasma spraying［J］. International Journal of Heat and Mass Transfer， 2020， 150： 119267.
20	崔长文. 等离子喷涂涂层形成过程数值模拟［D］. 福州：福州大学， 2011.
21	ZHANG M Y，ZHANG H，ZHENG L L.Numerical investigation of substrate melting and deformation during thermal spray coating by sph method［J］. Plasma Chemistry and Plasma Processing，2009，29（1）：55⁃68.
22	JLEE J， SUBEDI K K， HUANG G W， et al. Numerical investigation of YSZ droplet impact on a heated wall for thermal spray application［J］. Journal of Thermal Spray Technology， 2022， 31（7）： 2039⁃2049.
23	VINCENT S， BOT C L， SCRRET F， et al. Penalty and eulerian⁃lagrangian VOF methods for impact and solidification of metal droplets plasma spray process［J］. Computers & Fluids， 2015， 113： 32⁃41.
24	ZHU Z H， KAMNIS S， GU S. Numerical study of molten and semi⁃molten ceramic impingement by using coupled Eulerian and Lagrangian method［J］. Acta Materialia， 2015， 90： 77⁃87.
25	DHIMAN R，MCDONALD A G，CHANDRA S. Predicting splat morphology in a thermal spray process［J］. Surface and Coatings Technology，2008，201（18）：7789⁃7801
26	DHIMAN R， CHANDRA S. Freezing⁃induced splashing during impact of molten metal droplets with high Weber numbers［J］. International Journal of Heat and Mass Transfer， 2005， 48（25⁃26）： 5625⁃5638.
27	BRACKBILL J U，KOTHE D B，ZEMACH C.A continuum method for modeling surface tension［J］. Journal of Computational Physics，1992，100（2）：335⁃354
28	ALAVI S， PASSANDIDEH⁃FARD M， MOSTAGHIMI J， et al. Simulation of semi⁃molten particle impacts including heat transfer and phase change［J］. Journal of Thermal Spray Technology， 2012， 21（6）： 1278⁃1293.

[1]	Ming Cai, Tao Zhu, Xingjun Gao, Jinqi Bao. Research Status of Grinding Technology of Nickel⁃Based Superalloy [J]. Journal of Liaoning Petrochemical University, 2023, 43(3): 60-68.
[2]	Jianwei Wei, Huaijia Fu, Jiling Liang, Han He, Tingting Han, Yan Zhang, Jie Han. Inquiry Investigation about Solidification/Stabilization of Surplus Sludge Using Silicate Cement [J]. Journal of Liaoning Petrochemical University, 2023, 43(2): 7-12.
[3]	Huang Renshu, Yao Jinhuan, Liang Xiaoli, Jin Xiuying, Li Yanwei. Electrochemical Performances of Ni/Al⁃LDHs/rGO Composites Prepared by Homogeneous Precipitation Method [J]. Journal of Liaoning Petrochemical University, 2020, 40(4): 80-86.
[4]	Zhang Chu，Wang Shuang. Experimental Study on Melting Treatment of Fly Ash of MSW [J]. Journal of Liaoning Petrochemical University, 2019, 39(6): 31-35.
[5]	Wu Zhiyong,Liu Yang,Gao Yang,et al. An Investigation on the Time Relaxation Parameter Used in Boiling  Simulation of Helical Coil Heat Exchanger ShellSide [J]. Journal of Liaoning Petrochemical University, 2017, 37(5): 53-60.
[6]	Shi Ruotong， Deng Zilong， Gao Xingjun， Zhang Shaoyu， Luo Lin. Simulation Study on Residual Stress of Nickel-Based Superalloys Based on Deform-3D [J]. Journal of Liaoning Petrochemical University, 2017, 37(4): 49-52.
[7]	Jiang Lifeng,Zhang Guangwei. Study on the Microstructure and Wear/Corrosion Resistance of WC-10Co4Cr Coating Deposited by High Velocity Oxy-Fuel [J]. Journal of Liaoning Petrochemical University, 2017, 37(2): 54-59.
[8]	Li Xiuping, Yuan Zhe, Gong Xiaojie, Xia Baosen, Zhang Xuanrui, Zhao Rongxiang. Preparation of Nickel Ferrite Composite Oxide with Combustion and Its Photocatalytic Application [J]. Journal of Liaoning Petrochemical University, 2016, 36(2): 9-12.
[9]	Yan Zhe, Zhang Zhizhi, Lin Chunxia, Wang Jingyun, Fang Xiangchen. Research on the Impact of Ligand on the Stability of Nickelalactones [J]. Journal of Liaoning Petrochemical University, 2015, 35(5): 14-17.
[10]	Chang Fangyuan， Ma Guiyang， An Lijiao， Li Ze， Sun Miao. The Study on Flow Pattern of ThreePhase Flow in Mutation Pipe [J]. Journal of Liaoning Petrochemical University, 2015, 35(4): 26-29.
[11]	Dong Cunwu, Ye Jianming, Zhang Xia, Meng Maoyong. The Extraction of Nickel and Cobalt from MultiMetal Ionic  Solution by P507 and P204 [J]. Journal of Liaoning Petrochemical University, 2014, 34(3): 26-28.
[12]	XUAN Li-wei，WANG Huan,ZHANG Ji-qing，WANG Hai-yan， MENG Xiu-hong. Preparation and Diesel Oil Dehydrocracking Activity of  Large Pore Ni2P/γ-A12O3 Catalyst [J]. Journal of Liaoning Petrochemical University, 2012, 32(3): 25-28.
[13]	LI Li-hua, ZHANG Jin-sheng*, YANG Jin-guang. Determination of Nickel in Ordinary Alloy Steels by Microwave Digestion Spectroscopy [J]. Journal of Liaoning Petrochemical University, 2010, 30(1): 30-32.
[14]	ZHANG Jin-sheng, LI Li- hua, CHEN Yu-yan. Determination of Cu、Zn and Ni in Waste Active Muddy Soil by Microwave Digestion-FAAS [J]. Journal of Liaoning Petrochemical University, 2009, 29(4): 24-26.
[15]	WANG Rui, YANG Xiao-na, GONG Hong. Synthesis and Characterization of Nickel(Ⅱ) Complex of 2-Hydroxy-4-Methoxybenzophenone [J]. Journal of Liaoning Petrochemical University, 2009, 29(3): 23-25.