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<p>This study investigates Wire Arc Spraying Atomization (WASA) of Ag925 powders through experiments and computational fluid dynamics simulations. Two frameworks were evaluated: a conventional Discrete Phase Model (DPM) and a hybrid Volume-of-Fluid–Discrete Phase Model (VOF–DPM) with adaptive mesh refinement. Experimental powders exhibited predominantly spherical morphology with a particle size distribution centered around 45–50&#xa0;μm. Statistical goodness-of-fit tests (Chi-square, Kolmogorov–Smirnov, Anderson–Darling) confirmed that both simulations deviate significantly from experiment, though VOF–DPM consistently achieves closer agreement. In addition to improved predictions of surface-area–weighted mean diameter (D<sub>32</sub>), VOF–DPM reproduced morphological features such as irregular breakup and circularity values more consistent with experiment, unlike the idealized sphericity assumed in DPM. These results highlight the importance of resolving primary and secondary breakup mechanisms to capture both PSD and morphology. Limitations include constant material properties, reduced computational domains, and simplified particle assumptions, which suggest clear directions for refinement in future work.</p>

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Experiment–simulation synergy on multiscale breakup dynamics in wire arc spray atomization

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年11月19日

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  • Matee Sukkee,
  • Phanphong Kongphan

摘要

This study investigates Wire Arc Spraying Atomization (WASA) of Ag925 powders through experiments and computational fluid dynamics simulations. Two frameworks were evaluated: a conventional Discrete Phase Model (DPM) and a hybrid Volume-of-Fluid–Discrete Phase Model (VOF–DPM) with adaptive mesh refinement. Experimental powders exhibited predominantly spherical morphology with a particle size distribution centered around 45–50 μm. Statistical goodness-of-fit tests (Chi-square, Kolmogorov–Smirnov, Anderson–Darling) confirmed that both simulations deviate significantly from experiment, though VOF–DPM consistently achieves closer agreement. In addition to improved predictions of surface-area–weighted mean diameter (D32), VOF–DPM reproduced morphological features such as irregular breakup and circularity values more consistent with experiment, unlike the idealized sphericity assumed in DPM. These results highlight the importance of resolving primary and secondary breakup mechanisms to capture both PSD and morphology. Limitations include constant material properties, reduced computational domains, and simplified particle assumptions, which suggest clear directions for refinement in future work.