Abstract
A three-dimensional model of particle splatting on rough surfaces has been developed for high-velocity oxyfuel (HVOF) sprayed polymer particles and related to experimentally observed polymer splats. Fluid flow and particle deformation were predicted using a volume of fluid (VoF) method using Flow-3D software. Splatting behavior and final splat shapes were simulated on a realistic rough surface, generated by optical interferometry of an actual grit-blasted steel surface. Predicted splat shapes were compared with scanning electron microscopy images of nylon 11 splats deposited onto grit-blasted steel substrates. Rough substrates led to the formation of fingers and other asymmetric three-dimensional instabilities that are seldom observed in simulations of polymer splatting on smooth substrates.
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