A high resolution numerical model has been developed to simulate the simultaneous spreading and solidification of single and multiple-splat on a cold substrate. The model combines the level set formulation with curvilinear adaptive finite volume scheme to predict the deforming shape of the splat's free surface as well as the solidification interface shape and dynamics. An adaptive grid generation captures the solidification front and the level set formulation allows the free surface deformation caused by merging and separation. Numerical results on spreading, merging and solidification of a single splat and two splats are presented to demonstrate the capability of the scheme. It also shows that this model can be extended to predict porosity in thermal spray coatings.

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