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Guo K, Liu C, Chen W, Luo C, Li J. CFD Modeling of Primary Breakup in an EIGA Atomizer for Titanium Alloy Powder Production. MATERIALS (BASEL, SWITZERLAND) 2023; 16:5900. [PMID: 37687593 PMCID: PMC10489089 DOI: 10.3390/ma16175900] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 07/03/2023] [Revised: 08/05/2023] [Accepted: 08/08/2023] [Indexed: 09/10/2023]
Abstract
Electrode induction melting gas atomization (EIGA) technology is a commonly used and effective method for producing spherical metal powders in additive manufacturing. In this paper, we aim to describe the atomization and fragmentation of liquid sheets from a typical swirl nozzle and highlight the primary breakup of titanium alloy powder production. We developed a computational fluid dynamics (CFD) approach to simulate the primary disintegration process of the molten metal using the volume of fluid (VOF) method coupled with the large eddy simulation turbulence model (LES). Our numerical results show that high-speed spraying creates supersonic airflow in the atomization chamber. Recirculation is the main area where primary atomization occurs. The formation of the recirculation zone is the direct driving force that allows atomization to proceed, which will increase turbulence intensity and achieve higher atomization efficiency. VOF-LES simulation can capture some qualitative results such as conical melt-sheet shape, wave formation, ligament formation, and perforation formation. The primary droplet size mainly ranges between 200 and 800 μm. Finally, with increasing gas pressure, the particle size of the atomized powder gradually decreases, and the particle size distribution becomes narrower.
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Affiliation(s)
- Kuaikuai Guo
- School of Metallurgy, Northeastern University, Shenyang 110819, China;
| | - Changsheng Liu
- School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
| | - Wei Chen
- Baosteel Roll Science & Technology Co., Ltd., Changzhou 213019, China
| | - Chang Luo
- Baosteel Roll Science & Technology Co., Ltd., Changzhou 213019, China
| | - Jianzhong Li
- School of Metallurgy, Northeastern University, Shenyang 110819, China;
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Wu J, Xia M, Wang J, Zhao B, Ge C. Effect of Electrode Induction Melting Gas Atomization on Powder Quality: Satellite Formation Mechanism and Pressure. MATERIALS (BASEL, SWITZERLAND) 2023; 16:2499. [PMID: 36984378 PMCID: PMC10055927 DOI: 10.3390/ma16062499] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 02/23/2023] [Revised: 03/13/2023] [Accepted: 03/19/2023] [Indexed: 06/18/2023]
Abstract
Electrode induction melting gas atomization (EIGA) is a wildly applied method for preparing ultra-clean and spherical metal powders, which is a completely crucible-free melting and atomization process. Based on several experiments, we found that although the sphericity of metal powders prepared by EIGA was higher than that of other atomization methods, there were still some satellite powders. To understand the formation mechanism of the satellite, a computational fluid dynamics (CFD) approach FLUENT and a discrete particle model (DPM) were developed to simulate the gas atomization process, and several EIGA experiments with different argon pressures (2.5-4.0 MPa) were designed. A numerical simulation of the gas-flow field verified the formation trajectory of satellites, and the Hall flow rate of the powder produced under different pressures was 13.3, 13.8, 15.6, and 16.8, which were consistent with the prediction of the numerical simulation. This study provides theoretical support for understanding the satellite formation mechanism and improving powder sphericity in the EIGA process.
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Affiliation(s)
| | - Min Xia
- Correspondence: (M.X.); (C.G.); Tel.: +86-186-1253-7338 (M.X.); +86-(010)-6233-3642 (C.G.)
| | | | | | - Changchun Ge
- Correspondence: (M.X.); (C.G.); Tel.: +86-186-1253-7338 (M.X.); +86-(010)-6233-3642 (C.G.)
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Mandal S, Sadeghianjahromi A, Wang CC. Experimental and numerical investigations on molten metal atomization techniques – A critical review. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103809] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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Kumar A, Sahu S. Preheated liquid jet breakup dynamics in a twin-fluid injector. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.117723] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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Hussain S, Buss L, Yao D, Fritsching U, Uhlenwinkel V. Droplet velocity and thermal state from hot gas atomization of steel melt: Impact on the quality of the spray-formed tubular deposit. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103640] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Abstract
Due to the significant reduction in water droplet size caused by the strong air-water interaction in the spray nozzle, air-mist spray is one of the promising technologies for achieving high-rate heat transfer. This study numerically analyzed air-mist spray produced by a flat-fan atomizer using three-dimensional computational fluid dynamics simulations, and a multivariable linear regression was used to develop a correlation to predict the heat transfer coefficient using the casting operating conditions such as air-pressure, water flow rate, casting speed, and standoff distance. A four-step simulation approach was used to simulate the air-mist spray cooling capturing the turbulence and mixing of the two fluids in the nozzle, droplet formation, droplet transport and impingement heat transfer. Validations were made on the droplet size and on the VOF-DPM model which were in good agreement with experimental results. A 33% increase in air pressure increases the lumped HTC by 3.09 ± 2.07% depending on the other casting parameters while an 85% increase in water flow rate reduces the lumped HTC by 4.61 ± 2.57%. For casting speed, a 6.5% decrease in casting speed results in a 1.78 ± 1.42% increase in the lumped HTC. The results from this study would provide useful information in the continuous casting operations and optimization.
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Onwuka O, Unachukwu G, Nwanya S. Design and development of a brush atomization machine for metal powder production. SCIENTIFIC AFRICAN 2021. [DOI: 10.1016/j.sciaf.2021.e00986] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022] Open
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Qi H, Zhou X, Li J, Hu Y, Xu L. Performance Testing and Rapid Solidification Behavior of Stainless Steel Powders Prepared by Gas Atomization. MATERIALS 2021; 14:ma14185188. [PMID: 34576408 PMCID: PMC8471774 DOI: 10.3390/ma14185188] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 07/21/2021] [Revised: 08/27/2021] [Accepted: 09/02/2021] [Indexed: 11/16/2022]
Abstract
Gas atomization is a widely used method to produce the raw powder materials for additive manufacturing (AM) usage. After the metal alloy is melted to fusion, gas atomization involves two relatively independent processes: liquid breakup and droplet solidification. In this paper, the solidification behavior of powder during solidification is analyzed by testing the powder’s properties and observing microstructure of a martensitic stainless steel (FeCrNiBSiNb). The powder prepared by gas atomization has high sphericity and smooth surface, and the yield of qualified fine powder is 35%. The powder has typical rapid solidification structure. Collision between powders not only promotes nucleation, but also produces more satellite powder. The segregation of elements in powder is smaller as the result of high cooling rate which can reaches 4.2 × 105 K/s in average. Overall, the powder prepared by gas atomization is found to have good comprehensive properties, desired microstructure, and accurate chemical component, and it is suitable for various additive manufacturing techniques.
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Affiliation(s)
- Hang Qi
- State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China; (H.Q.); (Y.H.); (L.X.)
| | - Xianglin Zhou
- State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China; (H.Q.); (Y.H.); (L.X.)
- Correspondence: ; Tel.: +86-10-8237-5385
| | - Jinghao Li
- Department of Mechanical Engineering, McGill University, Montreal, QC H2A 0C3, Canada;
| | - Yunfei Hu
- State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China; (H.Q.); (Y.H.); (L.X.)
| | - Lianghui Xu
- State Key Laboratory for Advanced Metals and Materials, University of Science and Technology Beijing, Beijing 100083, China; (H.Q.); (Y.H.); (L.X.)
- Chengdu Holy Industry Co., Ltd., Chengdu 610000, China
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Kumar A, Sahu S. Influence of nozzle geometry on primary and large-scale instabilities in coaxial injectors. Chem Eng Sci 2020. [DOI: 10.1016/j.ces.2020.115694] [Citation(s) in RCA: 19] [Impact Index Per Article: 4.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022]
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Tabeei A, Samimi A, Mohebbi-Kalhori D. CFD modeling of an industrial scale two-fluid nozzle fluidized bed granulator. Chem Eng Res Des 2020. [DOI: 10.1016/j.cherd.2020.05.020] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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Wei M, Chen S, Sun M, Liang J, Liu C, Wang M. Atomization simulation and preparation of 24CrNiMoY alloy steel powder using VIGA technology at high gas pressure. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.04.030] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Hanthanan Arachchilage K, Haghshenas M, Park S, Zhou L, Sohn Y, McWilliams B, Cho K, Kumar R. Numerical simulation of high-pressure gas atomization of two-phase flow: Effect of gas pressure on droplet size distribution. ADV POWDER TECHNOL 2019. [DOI: 10.1016/j.apt.2019.08.019] [Citation(s) in RCA: 15] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/26/2022]
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The identification of an accurate simulation approach to predict the effect of operational parameters on the particle size distribution (PSD) of powders produced by an industrial close-coupled gas atomiser. POWDER TECHNOL 2016. [DOI: 10.1016/j.powtec.2015.12.001] [Citation(s) in RCA: 24] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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14
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A Comprehensive Review on Fluid Dynamics and Transport of Suspension/Liquid Droplets and Particles in High-Velocity Oxygen-Fuel (HVOF) Thermal Spray. COATINGS 2015. [DOI: 10.3390/coatings5040576] [Citation(s) in RCA: 39] [Impact Index Per Article: 4.3] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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Tian XS, Zhao H, Liu HF, Li WF, Xu JL. Liquid entrainment behavior at the nozzle exit in coaxial gas–liquid jets. Chem Eng Sci 2014. [DOI: 10.1016/j.ces.2013.12.008] [Citation(s) in RCA: 8] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/25/2022]
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16
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CFD modeling and its validation of non-Newtonian fluid flow in a microparticle production process using fan jet nozzles. POWDER TECHNOL 2013. [DOI: 10.1016/j.powtec.2013.05.050] [Citation(s) in RCA: 5] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/21/2022]
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Zhao H, Liu HF, Xu JL, Li WF, Cheng W. Breakup and atomization of a round coal water slurry jet by an annular air jet. Chem Eng Sci 2012. [DOI: 10.1016/j.ces.2012.05.007] [Citation(s) in RCA: 55] [Impact Index Per Article: 4.6] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/28/2022]
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