CFD simulation of liquid Mg drop impact on an Al substrate for compound casting

![CDATA[In this paper, to investigate a compound casting process for creating Al coating layer for Mg alloy, a computational fluid dynamics (CFD) model is developed using the VOF method to simulate the molten Mg drop impact on the Al substrate at solid state. A spreading factor, which is the ratio to the varied diameter of the Mg droplet after impacting on the Al substrate and its initial diameter before the impact, is used to describe and measure the impact process generated by the Mg drop, which could be divided into several steps: spreading, retracting and oscillating, and equilibrium as final step. Some key parameters are investigated via parametric studies: impact velocities, initial diameters of drop, the temperature of the Al substrate, which have important influences on the quality of compound casting products. The spread diameter of the Mg drop increases when the impact velocity and initial diameter of drop increase. While the impact velocities and initial diameters of the drop are larger than critical values, the liquefied Mg may partially have bubbles. The higher the temperature of the Al substrate is, the larger the spread diameters could be obtained, though oscillating and equilibrium steps take more time to finish in the CFD simulations developed.]]