Process Optimization of Surface Morphology and Internal Quality Based on Metal Droplets Horizontal Lapped Deposition

During horizontal lapped deposition and solidification of an aluminum molten droplet onto an aluminum substrate, the effects of different process parameters on the surface morphology and interior quality of the specimens were studied. By researching the single metal droplet deposition behavior, a numerical model of horizontal lapped deposition was established, and the evolution of morphology and temperature of one, two, three and four molten droplets horizontal lapped deposition impacting a substrate surface at different time was analyzed and multiple droplets successively deposition experiments under the different simulation parameters were carried out. The results indicate that the comparison between numerical simulations and experiments shows a good agreement. The optimal parameters were obtained. This investigation is essential to implement effective process control in metal micro-droplet deposition manufacture and it provides technical support and reference for molten droplets horizontal lapped deposition process of the complex metal parts.