The effects of deposit thermal history on microstructure produced by uniform droplet spray forming

Uniform droplet spray forming is a process aimed at producing near-net-shape parts directly from the liquid melt by spraying micron-sized droplets onto a movable target. In spray forming, the solidification rate of the deposited material is a key parameter that influences its microstructure formation and consequently, its mechanical properties. Ideal deposit microstructure has fine grain size and minimal segregation. The purpose of this thesis is to quantify the effects of deposit thermal history on the microstructure produced by the UDS forming process. Experiments were conducted with Zn-20wt% Sn alloy droplets using different process parameters to vary the deposit solidification rate from 6⁰C/s to 27⁰C/s immediately after deposition. The temperature of the sprayed deposits was measured in situ with a fiber-optic infrared thermometer and a contact thermocouple. Furthermore, a 2-D axisymmetric finite element model was developed to predict the temperature of the deposit during and after deposition. The simulation results show that radial heat conduction cannot be neglected when the thermal diffusivity of the substrate material is comparable to the diffusivity of the deposit material. Simulation results showed good agreement with the measured temperature data. The resultant deposit microstructures were examined with scanning electron microscopy, which revealed that the deposit microstructure includes a mixture of solidified phases formed inside the droplets before impact.

Department dc:contributor.department

Massachusetts Institute of Technology. Dept. of Mechanical Engineering.

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2002

Author dc:creator

• Cherng, Jean-Pei Jeanie

Advisor dc:contributor.advisor

• Jung-Hoon Chun.

• Mechanical Engineering.

Statement dc:rights

• M.I.T. theses are protected by copyright. They may be viewed from this source for any purpose, but reproduction or distribution in any format is prohibited without written permission. See provided URL for inquiries about permission.

Licence dc:rights.uri

• http://dspace.mit.edu/handle/1721.1/7582

Language dc:language.iso

eng

Handle dc:identifier.uri

http://hdl.handle.net/1721.1/29921

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/29921