Numerical study of the solidification of successive thick metal layers

Impact and solidification of droplets onto a dry solid substrate generates thin or thick substrates depending on size, velocity and physical properties of the fluid particles (during spray or deposition, for example). Numerous and complex phenomena occur in such processes. Difficulties are due to a lack of control of the resulting film, since fluid dynamics (due to droplets impact, for example) heat transfer and solidification interact and influence the final shape and properties of the film.This paper proposes the numerical study of the influence of some material properties upon the manufacturing of a thick coating. For this purpose, a simplified 1D model is used to simulate “deposition” and solidification of successive metal layers upon an initially cold substrate, assuming that there is no fluid flow. Then, the influence of several parameters is studied: layers thickness, initial substrate and layers temperatures, thermal contact resistance between two elements (substrate or layer) and impact frequency.