Melt metal sheet breaking mechanism of close-coupled gas atomization

The gas atomization is the process that a liquid mass is disintegrated into a collection of liquid melt droplets by the impact of high velocity gas stream and solidified into metal particles. However, the liquid melt sheet breaking mechanism has not been fully understood. So the experimental research was carried out under the condition of lower melt superheat. The results reveal that there are three approaches about melt metal sheet＇s breakage： from the edges of sheets, from inner surface of sheets, and disrupted by other droplets and sheets. The approach of melt sheet breakage is dependent on its thickness. The thicker sheets （above 25μm） are disintegrated mainly by the way of droplet＇s departing from edges, and the thinner sheets （below 10 μm） are chiefly breaking from the inner surface.     

紧耦合雾化制备Al86Ni6Y4.5Co2La1.5非晶粉末及其表征分析

利用扫描电子显微镜、X射线衍射仪、X射线光电子能谱分析仪、粒度分析仪、差示扫描热量仪和显微硬度仪对采用紧耦合雾化方法制备的Al_(86)Ni_6Y_(4.5)Co_2La_(1.5)非晶合金粉末的微观结构、表面元素、粒径分布、热稳定性以及显微硬度进行了分析。结果表明,大部分粉末(约为80%)的粒径小于45μm,主要由非晶相和纳米晶化相组成,其晶化演变过程为非晶→非晶′+fcc-Al→fcc-Al+AlNiY+Al_2Y;粉末表面存在厚度约为180.81nm的Al_2O_3氧化层,硬度在3000MPa以上。     

Numerical investigation on flow process of liquid metals in melt delivery nozzle during gas atomization process for fine metal powder production

Based on volume of fluid (VoF) interface capturing method and shear-stress transport (SST) k-ω turbulence model, numerical simulation was performed to reveal the flow mechanism of metal melts in melt delivery nozzle (MDN) during gas atomization (GA) process. The experimental validation indicated that the numerical models could give a reasonable prediction on the melt flow process in the MDN. With the decrease of the MDN inner-diameter, the melt flow resistance increased for both molten aluminum and iron, especially achieving an order of 10² kPa in the case of the MDN inner-diameter ≤1 mm. Based on the conventional GA process, the positive pressure was imposed on the viscous aluminum alloy melt to overcome its flow resistance in the MDN, thus producing powders under different MDN inner-diameters. When the MDN inner-diameter was reduced from 4 to 2 mm, the yield of fine powder (<150 μm) soared from 54.7% to 94.2%. The surface quality of powders has also been improved when using a smaller inner-diameter MDN.     

气雾化参数对SLM用1720 MPa级马氏体时效钢粉末特性的影响

利用真空感应熔炼气雾化法制备1720 MPa级马氏体时效钢粉末,研究雾化压力、过热度、气体加热温度对粉末特性的影响。结果表明,当雾化压力较高、过热度较高、气体加热温度较高的情况下,金属粉末的细粉收得率较大,松装密度较高,流动性较好。最佳雾化参数为漏嘴孔径ϕ5 mm、雾化压力5.0 MPa、过热度245 K、雾化气体温度100 ℃。该工艺条件下的时效钢粉末球形度良好,粉末流动性为20.15 s/50 g,松装密度为4.23 g/cm。     

Effect of closed-couple gas atomization pressure on the performances of Al-20Sn-1 Cu powders

Al-20Sn-1 Cu powders were prepared by gas atomization in an argon atmosphere with atomizing pressures of 1.1 and 1.6 MPa.The characteristics of the powders are determined by means of dry sieving,scanning electron microscopy (SEM),optical microscopy (OM),and X-ray diffractometry (XRD).The results show that the powders exhibit a bimodal size distribution and a higher gas pressure results in a broad size distribution.All particles in both cases are spherical or nearly spherical and satellites form on the surface of coarse particles.Dendritic and cellular structures coexist in the particle.With decreasing particle diameter,the secondary dendrite arm spacing (SDAS) decreases and the cooling rate increases.The particles processed under high gas atomization pressure (1.6 MPa) exhibit a lower SDAS value and a higher cooling rate than those of the same size under low gas atomization pressure (1.1 MPa).The XRD results show that the Sn content increases with decreasing particle size.     

Effects of combinatorial water atomization on microstructures and properties of Cu-Sn powder

A couple of additional cooling nozzles were assembled under traditional atomization nozzles in order to improve the process and produce the powder with fine microstructure and low oxygen. The influence of the process parameters on the properties of the powder was investigated. The results show that fmer powders with lower oxygen content and more irregular shape can be achieved by combinatorial atomizing process comparing with normal one under the same atomizing pressure.     

The influence of the pressure formation at the tip of the melt delivery tube on tin powder size and gas/melt ratio in gas atomization method

The production of metal powder using gas atomization technique is a wide spread process for manufacturing a wide range of spherical metal powder alloys. Metal powder properties generally improve with smaller powder particle size. Close-coupled atomizers are of great interest and controlling their performance parameters is critical for metal powder producing industries. In this study a new designed close-coupled nozzle system was used to produce tin powder to investigate the effect of the protrusion length of the melt delivery tube on the pressure formation at the melt tip. Observed improvement in particle refinement cannot be directly attributed to an increase in atomizing pressures and gas kinetics. Results from this study indicated that the observed metal flow rate was not behaving as what was earlier assumed, namely that, deeper aspiration enhanced metal flow rate. The melt flow rate was reduced with increasing the atomizing gas pressure. So that gas to melt mass flow ratio was increased for the same protrusion length and this ratio increase caused the finer powder particle size.     

紧耦合气雾化制备Al基合金非晶粉末的研究

研究了紧耦合气雾化制粉过程中AlNiY合金熔滴的冷却行为以及非晶颗粒的形成机制.结果表明：（1）AlNiY合金非晶化的临界冷却速率大致为10^3K/s;（2）熔滴的冷却速率与直径成反比,当直径小于25 μm时,熔滴达到临界冷却速率实现非晶化.当直径大于25μm时,熔滴无法获得非晶化临界冷却速率,只能发生形核结晶;（3）熔滴的非晶化还与雾化过程相关,由于熔滴破碎时的位置和温度不同,获得的冷却速率将不同,出现了相同直径（小于25 μm）的颗粒存在非晶和结晶两种状态.     

Characterization of spherical AlSi10Mg powder produced by double-nozzle gas atomization using different parameters

A self-developed double-nozzle gas atomization technique was used to produce AlSi10Mg powder. Effects of delivery tube diameter, gas pressure, and melt superheat on powder characteristics were investigated. The concepts of bluntness and outgrowth were introduced to analyze powder sphericity and satellite index quantitatively. The results showed that the median diameters of all atomized powders ranged from 25 to 33 µm. The highest yield rate (72.13%) of fine powder (<50 μm) was obtained at a superheat of 350 K. The powder size decreased with increasing melt superheat but increased with increasing delivery tube diameter. Powders with bluntness values between 96% and 98% accounted for over 60%. The outgrowth values demonstrated that 70%?85% of all powders did not contain satellite particles, with few powders adhered two or three particles. Not only Al and Si phases were present but also a metastable Al₉Si phase was detected.     

一种新型的气体雾化制粉方法

在传统气体雾化的基础上, 提出了一种新型的气体雾化制粉方法, 即在雾化气流中添加NaCl粉末, 提高气流的冲击动量. 通过对6-6-3青铜, Al, Al-Si, Pb, Sn, Zn等多种材料进行的雾化实验结果表明, 该方法能够有效减小雾化粉末的粒度, 与传统气体雾化相比, 平均粒度可减小50%, 此外还可大幅提高细粉收得率, 且不会过多影响粉末的纯度.     

基于Laval喷嘴的层流气雾化法工艺参数探索及粉末性能研究

基于Laval喷嘴的层流气雾化技术可以高效制备高性能金属粉末,但目前对这种技术的各项工艺参数及粉末性能尚未有系统性研究。本工作使用基于Laval喷嘴的层流气雾化制粉设备制备了AlSi10Mg合金粉末,同时使用传统分析方法和X射线计算机断层扫描技术分别研究了雾化气体压力以及导流管内径对粉末整体形貌、三维形貌、球形度、粒度分布、物理性能及内部缺陷的影响,并结合数值模拟进行机理性解释。结果表明,基于Laval喷嘴的层流气雾化技术制备的AlSi10Mg粉末性能较好,由于在较高的雾化气体压力和较窄的导流管内径条件下气液流量比更高,金属熔体更易发生破碎,故制备的粉末球形度更好,粒度分布较窄,细粉收得率可接近50%,不规则粉末及空心粉较少。     

Comparative study on the flow fields of three atomization nozzles

In this paper, the flow fields of three types of nozzles （ Hartmann, Laval and Laminar nozzles ） under the same conditions are simulated, and the corresponding to pressure, temperature, velocity and turbulence intensity are obtained. The results suggest that two crushing presents in the atomization process using Hartmann nozzle, but only one crushing presents in the atomization process using the other nozzles, through the comparative research on the flow field features of three types of nozzle. Furthermore, the shockwave plays a more important role in crushing of liquid metal than velocity.     

金属液流的气固两相流雾化破碎准则(英文)

介绍了一种自行发明的新的雾化方法。该方法是采用含有固体介质的高速气流即气固两相流对液体金属或合金进行雾化而制备粉末的一种方法,对比研究了同等条件下普通气体雾化与两相流雾化制备粉末的特征,研究了固体雾化过程中主要工艺参数对固体雾化粉末特征的影响规律。结果表明,两相流雾化制得粉末的平均粒度约为普通气体雾化所得粉末的二分之一,而且粒度分布更集中,粉末的冷却速度比普通气体雾化高一个数量级,粉末微观组织更细小;采用液体雾化破碎准则韦伯数以衡量雾化介质的破碎能力,得出两相流雾化介质的韦伯数为气体韦伯数和颗粒流韦伯数之和,建立了两相流雾化破碎的临界方程,并以此讨论了主要工艺规律。     

熔体过热处理对Al-4.7%Cu合金定向凝固组织的影响

分别在750、850、950和1050℃下，研究熔体过热处理对Al-4．7％Cu（质量分数）合金定向凝固组织的影响，利用综合热分析仪测定Al-4．7％Cu合金熔体结构特征及变化过程。结果表明：经过950℃和1050℃过热处理的一次枝晶间距比在750℃常规过热直接定向凝固的分别减小了31．2％和36．2％；随着熔体过热时间的延长，一次枝晶间距减小，组织越来越细密；但随着低温保持时间的延长，一次枝晶间距增大，组织越来越粗大，表明熔体高温处理对定向凝固组织形态的影响逐渐衰退；熔体过热处理对Al-4．7％Cu合金定向凝固组织有显著影响的原因在于熔体过热处理改变了熔体结构状态。     

气固两相流雾化法制备微细不锈钢粉末

采用含有固体食盐颗粒的气固两相流雾化工艺制备不锈钢粉末,并讨论了金属液流量、固体介质流量、气体介质流量以及气压等工艺参数对粉末粒度和形貌的影响.研究结果表明:在同等气体压力和流量的条件下,与普通气体雾化相比,气固两相流雾化所得不锈钢粉末具有更小的粒度和更好的球形度;随着气体介质流量及压力的增加,所制备的不锈钢粉末粒度越小,粉末的分布更集中;随固体介质盐流量的增大,所得粉末的粒度呈现先减小后增大的趋势.在熔体温度为1550℃～1 600℃,气体压力为0.9 MPa,气体介质流量为6 m3/min,金属液流量为42 g/s,盐流量为58 g/s条件下,制备出平均粒径为20 μm和球形度良好的不锈钢粉末.     

开涡状况下紧耦合气雾化的成膜机理

为了探明紧耦合气雾化制粉过程中金属熔液在气流作用下的雾化机理,采用降低金属过热度,使部分金属液流在雾化过程中提前凝固的方法,研究了开涡状况下(气体压力为2.1 MPa)金属液流的成膜机制.结果表明:雾化过程中液膜不是连续生成的,而是以离散方式形成的;开涡状况下的"实心锥"雾化存在将液滴挤压成液膜的成膜过程.这个成膜过程可表述为:金属液流进入回流区,经"初次雾化"破碎成离散的液滴,并在湍流层中进一步破碎细化,从滞留点前端穿过马赫盘,被挤压成厚度约为10～30μm、面积大约为10～50 mm2的液膜.     

真空感应熔炼气体雾化过程中钢包喷嘴堵塞:导流管几何形状的影响

研究了真空感应熔炼气体雾化（VIGA）技术中喷嘴堵塞的过程。为了更准确地了解导流管顶端形状对喷嘴堵塞的影响,采用计算模拟流体体积界面跟踪方法,对一次雾化区的两相流进行了模拟。结果表明,导流管末端的小平台是导致喷嘴堵塞的关键因素。因此,改进了输送管的扩张角（30°、35°、40°、45°）,缩短了小平台的宽度,解决了喷嘴堵塞的问题,实现了雾化连续性,提高了雾化效率。此外,当扩张角为40°~45°时,粉末具有较好的微观形貌,粒径为21~25 μm。不同改进角度下的数值模拟结果与实验结果显示出相似的趋势。本研究对了解VIGA工艺喷嘴堵塞过程具有指导意义和参考价值。     

一种新型的微细金属粉末气雾化喷嘴的设计

本文以气雾化、超声雾化和电荷表面效应等技术为基础,采用固体雾化与电场效应相结合,成功的设计了一种新型的固体与电场复合作用的二流雾化喷嘴,为雾化效果的明显提高,为细微金属粉末的制备提供了技术支持。     

Processing parameter effect on the splat diameters of the droplets produced by liquid metal atomization using De Laval nozzle

Liquid metal atomization with De Laval nozzle is not a widely used technique to produce metallic powders. It appears as a versatile process to manufacture different particle sizes according to the processing parameters (gas pressure, melt nozzle diameter, De Laval nozzle diameter, etc.). However, few studies have focused on the understanding of the different stages of the process. During the atomization process two pressure stages can be distinguished: transition time (pressurization time) and stabilized stage (setting pressure).The aim of the work is to study the effect of the operating parameters on the splat diameter during these two stages. Copper (99.9 at. %) was atomized using different sets of operating parameters on smooth steel substrates. Different splat shapes and mean equivalent diameters are observed and have shown that they depended on both, the atomization parameters and the atomization time.