电极感应熔化气雾化制粉技术中非限制式喷嘴雾化过程模拟

电极感应熔化气雾化(electrode induction melting gas atomization, EIGA)是一种制备超洁净无夹杂物的先进制粉技术,本文以粉末高温合金的氩气雾化过程为研究示例,对现有用于实际生产的国内某厂家提供的EIGA用非限制式喷嘴进行建模,采用商用计算流体力学软件FLUENT,分布采用欧拉-欧拉VOF(volume of fluid)多相流方法与欧拉-拉格朗日DPM (discrete phase model)离散相方法,对非限制式环缝喷嘴主雾化与二次雾化过程进行了数值模拟.通过对主雾化过程中多相流大涡模拟速度流场,主雾化过程中不同阶段高温熔体云图模拟以及二次雾化过程中TAB (Taylor analogy breakup)模型速度流场及TAB模型粒度分布的模拟研究,实现了对EIGA制粉技术中非限制式喷嘴雾化过程的全过程模拟,并预测了雾化后的粉末粒度分布.在此基础上,采用本文模拟使用的非限制式环缝喷嘴,设定与模拟条件一致(进气压力4 MPa,液流直径约4 mm)的实验条件,制备的粉末大部分颗粒的直径大小在100μm左右,该实验结果与模拟得到的粉末直径D50=100μm大小一致,进一步验证了模拟数据的合理性.该方法也适用于非限制式喷嘴里,其他金属或合金的雾化过的模拟研究.     

Close-coupled nozzle atomization integral simulation and powder preparation using vacuum induction gas atomization technology

We simulate the gas-atomization process of a close-coupled annular nozzle for vacuum induction gas atomization at a three-dimensional scale.Moreover,the relationship between the simulated droplet type and experimentally metallic powder is established by comparing the morphology of droplets with powders.Herein,the primary atomization process is described by the volume-of-fluid(VOF)approach,whereas the prediction of powder diameter after secondary atomization is realized by the VOF-Lagrangian method.In addition,to completely reflect the breaking and deformation process of the metallic flow,we employ the VOF model to simulate the secondary atomization process of a single ellipsoidal droplet.The results show that the primary atomization process includes the formation of surface liquid film,appearance of serrated ligaments,and shredding of ligaments.Further,gas recirculation zone plays an important role in formation of the umbrella-shaped liquid film.The secondary atomization process is divided into droplet convergence and dispersion stages,and the predicted powder diameter is basically consistent with the experiment.In general,the four main powder shapes are formed by the interaction of five different typical droplets.     

Process modeling gas atomization of close-coupled ring-hole nozzle for 316L stainless steel powder production

The paper aims at modeling and simulating the atomization process of the close-coupled ring-hole nozzle in vacuum induction gas atomization(VIGA) for metallic powder production. First of all, the primary atomization of the ring-hole nozzle is simulated by the volume of fluid(VOF) coupled large eddy simulation(LES) model. To simulate the secondary atomization process, we use the method of selecting the droplet sub-model and the VOF model. The results show that the ring-hole nozzle forms a gas recirculation zone at the bottom of the delivery tube, which is the main reason for the formation of an annular liquid film during the primary atomization. In addition, the primary atomization process of the ring-hole nozzle consists of three stages: the formation of the serrated liquid film tip, the appearance and shedding of the ligaments, and the fragmentation of ligaments. At the same time, the primary atomization mainly forms spherical droplets and long droplets, but only the long droplets can be reserved and proceed to the secondary atomization. Moreover,increasing the number of ring holes from 18 to 30, the mass median diameter(MMD, d50) of the primary atomized droplets decreases first and then increases, which is mainly due to the change of the thickness of the melt film. Moreover, the secondary atomization of the ring-hole nozzles is mainly in bag breakup mode and multimode breakup model, and bag breakup will result in the formation of hollow powder, which can be avoided by increasing the gas velocity.     

Consecutive induction melting of nickel-based superalloy in electrode induction gas atomization

The crucible-free electrode induction melting gas atomization(EIGA) technology is an advanced technology for preparing ultra-clean nickel-based superalloy powders. One of the key issues for fabricating powders with high quality and yield is the consecutive induction melting of a superalloy electrode. The coupling of a superalloy electrode and coil,frequency, output power, and heat conduction are investigated to improve the controllable electrode induction melting process. Numerical simulation results show that when the coil frequency is 400 kHz, the output power is 100 kW, superalloy liquid flow with a diameter of about 5 mm is not consecutive. When the coil frequency is reduced to 40 kHz, the output power is 120 kW, superalloy liquid flow is consecutive, and its diameter is about 7 mm.     

Production of Fine Particles from Melts of Metals or Highly Viscous Fluids by ultrasonic standing wave atomization

Ultrasonic standing wave atomization (USWA) is a new process capable of atomizing both high surface energy liquids and highly viscous liquids. Atomization is achieved through acoustic forces acting upon a liquid jet which is guided into the central pressure node of a standing wave field. Spherical metal powders with minimum mass median diameters of less than 15 μm have been produced from metal melts with surface tensions of about 0.5 N/m. Organic liquids with viscosities between 1 and 10 Pas have been atomized, yielding mass median diameters from 20 to 330 μm. The influence of different operating parameters on the mass median diameter of metal melts and highly viscous liquids was evaluated. Parameters which were varied were ambient gas pressure, vibration amplitude of the transducers, mass flow rate, density of liquid, viscosity of the liquid, surface tension and the outlet diameter. The powders and sprays were analyzed with laser diffraction particle sizers. The physical background of the atomization process is discussed and an equation for the prediction of the mass median diameter is derived.     

Ensemble and Single Particle Laser probe sizing results for gas atomized zinc powders

On-line characterization of powder and droplets during gas atomization of molten metals and alloys offers extensive opportunities for real-time process monitoring and control. The capability to make on-line measurements can significantly reduce tedious and costly powder classification, which, currently, is always carried out subsequent to the atomization process. Two laser-based particle sizing instruments, the EPCS (ensemble instrument) and PCSV (single particle instrument), were used during gas atomization of zinc with a double Coanda nozzle configuration. The laser instruments were positioned in the duct leading from the bottom of the atomization tower to the powder collection cyclone. The effect of gas to metal ratio on particle size was studied by varying the atomization gas pressure from 0.69 MPa to 1.03 MPa. Air was used as the atomizing gas for some of the 0.69 MPa runs, while nitrogen was used for all of the higher-pressure runs. Experimental apparatus and procedures for atomization and on-line powder sizing with the EPCS and PCSV are described. EPCS and PCSV measurements, which were compared with standard sieve analyses, indicate that the ensemble instrument is a good candidate for on-line process monitoring and control.     

Impact mechanism of gas temperature in metal powder production via gas atomization

This paper aims at studying the influence mechanism of gas temperatures(300 K, 400 K, 500 K, and 600 K) on gas atomization by simulating the integral atomization process of the close-coupled nozzle in vacuum induction gas atomization(VIGA). The primary atomization is simulated by the volume of fluid(VOF) approach, and the second atomization is studied by the discrete phase model(DPM) combined with the instability breakage model. The results show that, at an increased gas temperature, the influences of gas–liquid contact angle and gas temperature in the recirculation zone on the primary atomization are virtually negligible. However, increasing the gas temperature will increase the gas–liquid relative velocity near the recirculation zone and decrease the melt film thickness, which are the main reasons for the reduced mass median diameter(MMD, d50) of primary atomized droplets. During the secondary atomization, increasing the gas temperature from 300 K to 600 K results in an increase in the droplet dispersion angle, which is beneficial to the formation of spherical metal powder. In addition, increasing the gas temperature, the positive effect of gas–liquid relative velocity increase on droplets refinement overweighs the negative influence of the GMR decrease, resulting in the reduced MMD and diameter distribution interval. From the analysis of the atomization mechanism, the increase in atomization efficiency caused by increasing the temperature of the atomizing gas, including primary atomization and secondary atomization, is mainly due to the increase in the gas drag force difference between the inner and outer sides of the annular liquid film.     

Innovative technologies for powder metallurgy-based disk superalloys: Progress and proposal

Powder metallurgy(PM) superalloys are an important class of high temperature structural materials, key to the rotating components of aero engines. In the purview of the present challenges associated with PM superalloys, two novel approaches namely, powder preparation and the innovative spray-forming technique(for making turbine disk) are proposed and studied.Subsequently, advanced technologies like electrode-induction-melting gas atomization(EIGA), and spark-plasma discharge spheroidization(SPDS) are introduced, for ceramic-free superalloy powders. Presently, new processing routes are sought after for preparing finer and cleaner raw powders for disk superalloys. The progress of research in spray-formed PM superalloys is first summarized in detail. The spray-formed superalloy disks specifically exhibit excellent mechanical properties. This paper reviews the recent progress in innovative technologies for PM superalloys, with an emphasis on new ideas and approaches, central to the innovation driving techniques like powder processing and spray forming.     

Preparation of Fe–Si–B–Nb amorphous powder cores with excellent high-frequency magnetic properties

FeSiBNb amorphous powder cores were prepared with the amorphous powder by gas atomization and subsequent hot pressing of resulting powder after creating oxide layers on the amorphous powder. Fully amorphous FeSiBNb powders with good soft magnetic properties were successfully obtained in the particle size range below 100 μm. FeSiBNb amorphous powder cores exhibit stable permeability up to 10 MHz, showing excellent high-frequency characteristics.     

稀土硅铁雾化制粉机理的高速摄影分析

本文应用高速摄影技术对稀土硅铁雾化制粉过程进行了分析,讨讨了合金液滴的雾化机理并提出将雾化过程分为五个区域的理论,为雾化器构造的设计提供了可靠的数据资料。     

超声雾化法制取金属粉末方法研究

本文介绍了利用超声振动能量制取超细金属粉末的超声雾化方法，提出了超声制粉雾化室，等离子枪，阴极、阳极喷咀及换能器振动系统的最佳尺寸和工作参数，给出了实验结果及制得的粉末显微结构照片．实验结果表明，用本文所述方法制得的金属粉末组成为：－80目粉占84呢，－120目粉占63．7啪，而用PREP方法制得的粉末分别占19．5％和11．7％，由此看来，用本方法制取超细金属粉，在粒度组成方面优于PREP方法．文中还对粉末冷却速度做了估算，得到了粉末平均冷却速度大于1×10_5k/5     

Physicochemical Properties of TiN Powder Produced by Arc Discharge Technique

The physicochemical properties of ultrafine TiN powder produced by atomization of titanium in a low-pressure nitrogen-argon gas mixture are studied. It is shown that the TiN powder is composed of nanocrystalline particles with narrow particle-size distribution. The oxidation and recrystallization problems are discussed.     

结构参数变化对内混式喷嘴雾化性能的影响作用

通过对比6种结构参数不同的环形内混式喷嘴的雾化平均直径的变化规律,研究了喷嘴结构变化对雾化性能的 影响规律。结果表明,混合腔宽度、内喷嘴缩进长度、出口流程均对喷嘴雾化性能造成明显影响,而不同的混合腔长度、 气体及液体的喷入方式则基本上不影响雾化性能。     

Technical Note: Powder Production by Gas Atomization of Bioglass Melt

Bioglass melts are granulated by hot gas atomization techniques, where spherical powder and fiber type products are respectively available depending on different process parameters. Higher atomization gas temperatures induce higher powder fractions, while at ambient gas temperature fiber materials can be produced. The diameter of the as‐atomized fiber material decreases with increasing melt temperature. Particle size analysis, Scanning Electron Microscopy, and optical observation of the atomized materials are performed. The melt disintegration mechanism and the particle shape and size dependency on process parameters are discussed.     

激光熔覆中金属粉末粒子与激光相互作用模型

为了对同轴激光熔覆过程中运动的金属粉末粒子的速度和温度进行理论分析,并研究各工艺参量的影响,建立了运动中金属粉末粒子的运动模型和热模型.模拟结果表明,粉嘴几何尺寸、粒子直径以及气/粉两相流初始速度是影响粒子运动行为的重要因素;粉嘴几何尺寸、激光焦点位置、激光发散角、激光功率、粒子直径以及气/粉两相流初始速度是影响粒子热行为的重要因素.在相同的工艺参量下(粉嘴出口内径r=2 mm,粉嘴倾角α=60°,初始气流速度v0=0.8 m/s),基于数字粒子图像测速(DPIV)技术,对316L不锈钢粉末粒子运动模型进行了实验验证.结果表明,运动理论模型是可靠的.该模型是掌握同轴激光熔覆过程中金属粉末粒子运动行为的有效工具;同时,热模型也是分析粉末粒子温度随不同参量变化的重要工具.     

Concentration model based on movement model of powder flow in coaxial laser cladding

The structure below the coaxial nozzle is critical since the spatial distribution of metal powder particles determines the laser attenuation as well as catchment efficiency. It is difficult to simulate the powder concentration distribution, because the complex phenomena involved in the two-phase turbulence flow. In this paper, the air-powder flow is studied along with powder properties, nozzle geometries and shielding gas setting. A Gaussian model is established to quantitatively predict the powder stream concentration in order to facilitate coaxial nozzle design optimizations. An experimental setup is design to measure the powder concentration for this process. The simulated results are compared with the experimental results. This study shows that the powder concentration mode is influenced significantly by powder properties, nozzle geometries and shielding gas setting.     

Preparation and Characterization of Nano-structured Ceramic Powders Synthesized by Emulsion Combustion Method

The emulsion combustion method (ECM), a novel powder production process, was originally developed to synthesize nano-structured metal-oxide powders. Metal ions in the aqueous droplets were rapidly oxidized by the combustion of the surrounding flammable liquid. The ECM achieved a small reaction field and a short reaction period to fabricate the submicron-sized hollow ceramic particles with extremely thin wall and chemically homogeneous ceramic powder. Alumina, zirconia, zirconia–ceria solid solutions and barium titanate were synthesized by the ECM process. Alumina and zirconia powders were characterized to be metastable in crystalline phase and hollow structure. The wall thickness of alumina was about 10nm. The zirconia–ceria powders were found to be single-phase solid solutions for a wide composition range. These powders were characterized as equiaxed-shape, submicron-sized chemically homogeneous materials. The powder formation mechanism was investigated through the synthesis of barium titanate powder with different metal sources.     

Detailed simulation of primary atomization mechanisms in Diesel jet sprays (isolated identification of liquid jet tip effects)

In this study, the atomization characteristics of Diesel jet front tip have been investigated to elucidate the physical mechanisms by detailed numerical simulation. The computations are carried out with the finest grid resolutions ever that can resolve the final droplet generation by surface tension. The numerical methods are based on level-set interface tracking. The methods were validated by test cases and the grid resolution survey shows that the resolutions for the present study are sufficient. The present flow setup excludes nozzle disturbances to investigate how the disturbances from the liquid jet front would lead to atomization where the liquid jet impacts against the quiescent gas. The liquid jet front becomes an umbrella-like shape. From the front umbrella tip edge, ligament breakup first occurs. Ligament breakup is strongly correlated with the gas motion in the vicinity. The gas region behind the front is highly disturbed by atomization. By the gas recirculation motion here, air and some droplets are entrained and mixed. Also, the disturbances are fed back to the front umbrella by this motion and become synchronized with the breakup. Droplet pinch-off is mainly in the short-wave mode, but some ligaments are elongated by local gas stretch to finally have a long-wave mode shape, namely a mode shift occurs. The above findings of liquid jet front umbrella formation, atomization at the umbrella edge, mixing and atomization loop in the recirculation flow region and droplet generation mode give an insight to the modeling of droplet generation in actual sprays.     

铝和铝-锂合金的爆炸烧结试验研究

 本文研究了纯铝粉和快速凝固铝-锂合金粉的爆炸烧结工艺，测量了烧结体的密度，观察了烧结体内的微观组织和断口形貌。试验用粉末材料为水雾化铝粉、氮气雾化铝粉和氩气雾化铝-锂合金粉。试验时把粉末材料装在包套内，粉状炸药装在包套外的纸筒内，炸药从一端起爆。根据文中给出的爆炸烧结工艺参数的设计原则，通过系统地试验，已获得Φ17×70 mm的铝-锂棒材和Φ100×100 mm的纯铝棒材，相对密度超过98%，无中心孔（马赫孔）。微观组织和断口形貌观察结果表明：颗粒之间已达到焊接结合，结合区是由超细微晶组成，颗粒内部仍保持原始粉末的急冷组织。试验结果还表明：包套最终运动速度、包套内径、粉末材料强度、粉末材料表面氧化膜的厚度都是影响爆炸烧结质量的重要因素。     

氮气喷射成形FGH4095的组织特征

以氮气为雾化气体采用喷射成形工艺制备了FGH4095高温合金沉积坯, 记录了沉积过程坯体表面温度曲线, 并采用定量金相法、排水法测试了坯体致密度, 观察了坯体晶粒及γ'相的形貌. 结果表明采用氮气作为雾化介质进行喷射成型喷射沉积坯基体致密度可达99%以上, 但也存在着较大的(1—2μm)的气孔, 经热等静压和近等温锻后宏观气孔闭合, 氮以尺寸不超过1 μm的碳氮化物形式存在. 喷射沉积坯以等轴晶组织为主, 坯体内部平均晶粒尺寸约为20—40 μm, 近表面区域晶粒较细, 约为13 μm; 一次γ' 相多数呈尺寸约0.3—0.5 μm不规则块状形貌. 喷射成形坯组织结构的形成与喷射成形过程的降温过程有密切关系.