An inverse problem in modelling liquid metal spraying

This paper addresses some of the most important problems in modelling metal spray deposition processes: a spatial mass flux distribution within the spraying cone produced by the source, and a spraying efficiency in depositing material onto the substrate. The model is based on a continuous approach of the liquid metal spraying. The mass flux distribution function is derived from experimental observations and the mass preservation constraint. It depends on the source spray parameters and modelling functions. Upon impinging the substrate, liquid metal droplets disintegrate in a complex way. A fraction of the total mass arrived at remains in the point of impact, while the rest is splashed and re-deposited elsewhere. The ratio of the mass retained over the total mass arrived at is called the sticking efficiency. This parameter is found to be the solution of an inverse problem. The non-linear inverse problem is transformed into a boundary value problem, which is solved using methods for a curvilinear grid generation. The experimental data are obtained from stationary sprayed deposits. © 2003 Published by Elsevier Science Inc