Numerical and Experimental Research of Temperature of Arc Spray Zn‐Al Alloy Droplets

In this paper, a model for arc spraying Zn‐Al droplets during flight course has been established and developed using theoretical principles of fluid mechanics, heat transfer and phase transition. Mathematical models are set up to describe the interaction between air current and droplets in flight. The calculation results showed that Zn‐Al droplet’s velocity and temperature are the function of flight distance and droplet’s diameter. Percentage of solid droplets in metal spray is a function of droplet’s size distribution. Within a flight distance of 600 mm, depending on the size and cooling rate, the droplets in metal spray may be in the states of entirely liquid, partially solidified, or entirely solidified and the percentage of partially solidified and entirely solidified droplets in metal spray is less than 2%.