Abstract
We numerically study impingement and solidification of a molten hollow droplet onto a surface during thermal spray coating process. In the impingement model transient flow during the hollow droplet impact, subsequent spreading and solidification, and air entrapment are considered using the volume of fluid surface tracking method coupled with the solidification model within a one-domain continuum formulation. A phenomenon of counter liquid jetting is observed which causes large air entrapment and porous deposited layer. This will have potential prospects in improving the thermal insulation properties of surfaces in turbine blades, engine components applications.
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