The selection of the spray deposition rate during the spray rolling process

Abstract

This article presents a detailed theoretical analysis of the selection of the maximum and minimum spray deposition rates under steady-state conditions during the spray-rolling process. The following predictions are made on the basis of the preceding theoretical analysis. First, the key factor that may control the minimum spray deposition rate is either the removal of porosity or the removal of prior droplet boundaries. With an increase in initial liquid fraction at the deposit/roll interfaces, the mechanism changes from the former to the latter. Second, the mechanism that controls the maximum spray deposition rate is related to either the drag-in angle or the distance between the nozzle and the deposited material’s surface. With an increase in roll diameter or a decrease in distance between the nozzle and the roll-axis plane, the controlling mechanism is changed from the former to the latter. Third, both the calculated maximum and minimum spray deposition rates markedly increase with an increase in roll diameter and roll rotational frequency. In addition, the present theoretical analysis suggests that spray rolling can be optimized to manufacture strips with a high production rate.