In order to understand the solidification process of an atomized droplet and predict the fraction solidification ofdroplets with flight distance during spray forming, a numerical model based on the population dynamics approach isdeveloped to describe the microstructure evolution under the common action of the nucleation and growth of grains.The model is coupled with droplets heat transfer controlling equations and solved for Al-4.5 wt pct Cu alloy. It isdemonstrated that the numerical results describe the solidification process well.
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