Atomization Characteristics of Droplet and Morphologies of Arc Sprayed Ni-Al Particles and Composition Coatings

Droplet atomization characteristics and its morphology in twin-wire arc sprayed (TWAS) Ni-Al were explored in depth. Both numerical model and theoretical method were built for calculating the process of the droplet deformation and breakup in air flow, which based on the standard k-ε model and the volume of fluid (VOF) dual-phase flow model. The atomization characteristics of double droplets and three droplets were also studied in the atomization process by simulation. The micro structure and the morphology of the composite coatings were analyzed by SEM and TEM. The experimental results indicate that TWAS droplets are the process of explosive breakup or two steps breakup. Morphology of the TWAS prepared Ni-20wt.%Al and Ni-5wt.%Al particles was accordingly characterized by SEM. The phase compositions of the Ni-Al particles were obtained by EDS. By testing the velocity of sprayed particles, the change rule of particles with spray pressure was obtained. Ni twins are discovered in the Ni-Al coating due to rapid cooling in TWAS process.