A numerical model has been developed to simulate the distribution of polygonal grain size in a sprayed microstructure formed from an alloy droplet spray containing a large number of solid, mushy and liquid droplets. The model takes into account the effects of: (1) the droplet size distribution; (2) its corresponding distribution of solid, mushy and liquid droplets at the instant of deposition; (3) the overall thermal condition of the spray formed preform during final solidification. The model has been validated against experiments of the spray forming of Ni superalloy rings, with modelled grain size distributions giving good agreement with measurements obtained by electron backscatter diffraction.
Mi, J. W., & Grant, P. S. (2007). Numerical modelling of spray formed grain size evolution. Materials Science Forum, 561-565(PART 3), 1991-1994. doi:10.4028/www.scientific.net/msf.561-565.1991