Impact of Viscous Droplets on Dry and Wet Substrates for Spray Painting Processes

This paper presents numerical studies of the viscous droplet impact on dry and wetted solid walls for spray painting applications, focusing on air entrapment, film structure, and flake (flat pigment) orientation. The results were compared with experimental observations using various high-speed camera arrangements. For paint droplet impact on dry substrates, a dynamic contact angle model was developed and used in numerical simulations. This contact angle model was verified with experimental observations. For the droplet impact on wet surfaces, characteristic crater sizes (diameter and depth) were defined considering also the effect of the film thickness. A strong correlation with the droplet impact Reynolds number was observed. In addition, a user-defined 6DOF (6-degrees-of-freedom) solver was implemented in a CFD program to perform calculations of rigid body motions within the impacting droplet, technically relevant for the resulting effect of flakes in metallic effect paints. The developed models were applied in parameter studies to further clarify the existing dependencies on application and fluid parameters more quantitatively. The simulation results are helpful to understand and to improve painting processes with respect to the final quality parameters.