Abstract
In the paper a drop-on-demand deposition system using ultra-high frequency induction heating technology is proposed for the aim of depositing metal materials with high melting point onto the substrate at a low thermal input. The numerical model coupled with electromagnetic field, thermal field and flow field was established to investigate the metal transfer and thermal characteristics of the deposition process. Results indicate that the metal droplet can be deposited onto the substrate at a low thermal input. The effects of current frequency and current density on the deposition temperature and time duration of the deposition were also numerically studied. Analysis of the electromagnetic force and temperature of the pendent molten metal during deposition demonstrates that the current frequency as well as current density influences the time duration by determining the electromagnetic force and the heating rate. The numerical model was verified by experiments, and the experimental results show good agreement with the calculated results. With the advantage of depositing high melting point material while limiting the thermal input for the substrate, the drop-on-demand deposition method using ultra-high frequency induction heating technology is expected to be applied in metal droplet-based applications where the thermal-sensitive materials are used.
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