A simple transient numerical model for heat transfer and shape evolution during the production of rings by centrifugal spray deposition

Centrifugal spray deposition, the atomisation of a liquid metal by centrifugal force and the subsequent collection of the atomised droplets on a reciprocating collector, is currently being developed for the production of high performance Fe, Ni and Ti based ring-shaped components for use in aerospace and gas turbine containment applications. The process combines the technical, economic and metallurgical benefits of more conventional gas-assisted spray forming techniques with the advantage that it can easily operate under vacuum, reducing potential problems from gas entrapment and thermally induced porosity. In order to aid process development, understanding and optimisation, a transient numerical heat and mass transfer model has been developed that is capable of predicting the evolution of the deposit temperature distribution during spraying. The model has been validated experimentally using thermocouple measurements obtained during the production of 35 kg (340 mm diameter) IN718 rings and qualitative correlations have been observed between the predicted data and the type/distribution of porosity and second phase precipitates in the deposit. The model is currently being further developed and integrated with droplet size distribution and cooling models to provide a better insight into the physics and operational parameters which control deposit shape and microstructure. (C) 2004 Kluwer Academic Publishers.