Numerical Study on Successive Liquid Metal Alloy Droplet Depositions

Successive liquid metal alloy droplet impingements find extensive applications in additive manufacturing technologies and a detailed knowledge about the flow behavior, phase transformation and free surface deformation is required to have a complete understanding and optimization of the process parameters. Experimental research in this field is limited due to extremely small length and time scales involved. Numerical simulation of such process involves challenges like tracking deforming interfaces, modelling the successive droplets, surface tension, flow field and solidification. A non-isothermal enthalpy-based porosity model is used to numerically study the phase change characteristics of successive liquid metal droplet depositing onto a substrate. The flow governing equations are solved using the finite volume scheme. The Coupled Level Set Volume of Fluid (CLSVOF) method is used to track the free surface and the surface tension is modelled using the Continuum Surface Force (CSF) method. The splat morphology, phase change characteristics and effects of various impact conditions on successive columnar droplet depositions are examined.