Modeling of the in-flight solidification of droplets produced by the uniform-droplet spray process

A mathematical model to describe the solidification of the droplets produced by the uniform-droplet spray process is developed. The model addresses the motion, heat transfer, nucleation and solidification of traveling droplets. A dimensionless formulation for the interface migration scheme during recalescence is developed. The simulation results of Sn–5wt.%Pb alloy droplets subjected to electrical charging are compared with those in uncharged cases. The effects of charging voltage on scattering and subsequent changes in droplet velocities and heat transfer coefficients are analyzed. The computations show substantial increases in heat transfer coefficient upon charging and notable decreases in droplet velocities and cooling rates.