An Accuracy Evaluation for the Madejski Splat-Quench Solidification Model

Development of methods to spray form materials by precisely controlled deposition of droplets can result in new manufacturing processes which offer improved metallurgical performance and reduced production costs. These processes require a more detailed knowledge of the fluid mechanics, heat transfer and solidification that occur during droplet spreading. Previous work using computer simulations of this process have been difficult to implement and have required long running times. This paper examines the use of an alternative, simplified, method developed by Madjeski for solving for the problem of droplet spreading and solidification. These simplifications reduce the overall splat spreading and solidification problem to a closed-form differential equation. This differential equation is then solved under various conditions as reported from recent publications of experimental and numerical results of drop analysis. The results from the model are compared in terms of maximum splat diameter, minimum splat thickness, and time for the droplet spreading to reach 95% of the maximum diameter. The results indicate that the accuracy of the model can be improved by accounting for energy losses in the initial rate of droplet spreading. The model results show that the predictions of experimental results are improved to within 30% over a wide range of conditions.