Simulation of Billet Shapes Using Multiple Atomizers

Large-scale segregation-free castings are in high demand for aerospace applications, yet the production of large-sized spray-formed billets remains poorly defined. This research addresses the preparation of such billets. To address the preparation of large-scale spray-formed Al–Zn–Mg–Cu aluminum alloys, numerical simulation methods were employed to investigate the billet fabrication process in spray forming, and the distribution characteristics of pores within the billet were analyzed. The results indicate that the drawing speed of the substrate is the primary factor that controls the billet dimensions. The slower the drawing speed, the larger the billet diameter. The eccentric distance and incidence angle of the atomizer determine the flatness of the billets. With four atomizers positioned at eccentric distances of 141, 245, 316, and 375 mm; an incidence angle of 45°; scanning angles of 8°, 5°, 3°, and 1°; and a drawing speed of 0.1 mm/s, it is possible to produce large billets with a diameter of 800 mm. The pore distribution in the billet is characterized by a higher concentration at the periphery and a lower concentration at the center, with a tendency for pores to be more prevalent in the initial stage and decrease in the later stages.