Atomization simulation and preparation of 24CrNiMoY alloy steel powder using VIGA technology at high gas pressure

Wei, Mingwei; Chen, Suiyuan; Sun, Miao; Liang, Jing; Liu, Changsheng; Wang, Mei

doi:10.1016/j.powtec.2020.04.030

Cited by 62 publications

(19 citation statements)

References 31 publications

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“…On the one hand, the gas blast disturbs the fluid stream, facilitating fluid granulation and the generation of fine powders. According to previous studies on GA, the powder size decreases with increasing atomizing gas pressure 28 , 29 . On the other hand, the gas blast enhances the convective heat transfer between the fluid and atmosphere 30 , improving the cooling rate of the fluid pushed out of the electrode rim.…”

Section: Resultsmentioning

confidence: 77%

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Zhao

Cui

Numata

et al. 2020

Sci Rep

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In recent years, spherical powders with no or minimal internal pores fabricated by the plasma rotating electrode process (PREP) have been highly recommended for powder-type additive manufacturing. Most research on PREP is aimed at establishing relationship between PREP parameters and powder size. However, almost no dedicated research on granulation behavior has been conducted so far. In the present study, PREP experiments of Ti64 and SUS316 alloys were carried out. Numerical modeling based on computational thermo-fluid dynamics was developed to analyze the granulation behavior. In particular, the roles of the additionally introduced gas blast and the morphology of the electrode end surface in fluid granulation were preliminarily investigated. The study showed that in addition to the electrode's rotating speed and diameter, manipulating the plasma arc current (i.e., the melting rate) could also be an effective way to control the PREP-powder size. According to the simulation, there were competing actions of the gas blast affecting the powder size. The gas blast created disturbance on the fluid and deepened the depression of the electrode end surface, which facilitated powder refinement. However, the cooling effect enhanced the fluid stability and hindered fluid granulation. The conclusions indicated the possibility of using various methods to manipulate PREP-powder size.

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Section: Resultsmentioning

confidence: 77%

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Zhao

Cui

Numata

et al. 2020

Sci Rep

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“…Due to the advantages of high purity, good sphericity, low oxygen content and good fluidity, high-performance spherical metal powder is widely applied in powder metallurgy industry [1][2][3], surface spraying process [4], additive manufacturing [5,6], powder injection molding [7], and electronic packaging technology [8].…”

Section: Introductionmentioning

confidence: 99%

“…Many methods are used to prepare spherical metal powders, including vacuum induction melting gas atomization (VIGA) [8], electrode induction melting gas atomization (EIGA) [9], plasma inert-gas atomization (PIGA) [10], plasma rotating electrode process (PREP) [11], plasma spheroidization (PS) [12], and high-temperature remelting spheroidization (HRS) technology [13]. The gas atomization is the most wildly used technology for spherical metal powder production, which has wide particle size distribution.…”

Section: Introductionmentioning

confidence: 99%

Numerical simulation and experiment for the ultrasonic field characteristics of ultrasonic standing wave atomization

Gao

Guo

Dong

et al. 2021

J Braz. Soc. Mech. Sci. Eng.

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Ultrasonic standing wave atomization (USWA) can obtain micron-sized spherical droplets from high viscosity or high surface energy liquids, which mainly depend on the high-energy density of a sound field. In this paper, the formation of an ultrasonic field can be generated by the vibration of a tool head driven by magnetostrictive transmitters. Based on the simulation environment of Comsol Multiphysics software, the numerical study about the characteristics of ultrasonic standing wave sound field was carried out. The influence of the arrangement of transducer, the shape and parameters of transducer tool head, the length of resonator and the pressure of environment on the sound pressure was studied. Then, the influence of ultrasonic frequency on the ultrasonic standing wave sound field was studied. It could be seen that the sound pressure distribution is better when the double transmitters were facing each other, the length of the cavity was with n = 5 sound pressure nodes, and the tool head was spherical. On this basis, the influence of primary frequency (f = 20 kHz) on the sound pressure was analyzed, and the optimal ultrasonic frequency f = 19.8 kHz was obtained. The sound pressure of the ultrasonic standing wave field was measured, and the computed results were compared with the experimental results. Finally, based on the optimized parameters of the simulation, USWA was used to atomize glycerol-water solution with different concentrations. The experimental results showed that the ultrasonic standing wave field established can atomize glycerol aqueous solutions with viscosities from 1.01 × 10-3 Pa•s to 1200.58 × 10-3 Pa•s.

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“…Using the correct simulation models and precise thermophysical property data, the temperature distribution and history, fluid flows in the melt, porosity and other defect formation, as well as the formation of thermal stresses during the solidification in the additive manufacturing process can be predicted. [ 16 ] In a similar manner, this approach can also be used to improve simulation of other manufacturing processes, such as thermal spraying, laser cladding [ 17–20 ] and powder production by gas atomization [ 21,22 ] Consequently, process simulations based on precise thermophysical properties result in faster process development cycles.…”

Section: Introductionmentioning

confidence: 99%

Thermophysical Properties of an Fe_57.75Ni_19.25Mo₁₀C₅B₈ Glass‐Forming Alloy Measured in Microgravity

2020

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Due to their unique combination of properties, metallic glasses are of particular interest in numerous fields of engineering. [1] The much lower material cost, compared with Zr-based metallic glasses, [2] together with high corrosion and wear resistance, make Fe-based metallic glasses very attractive for industrial applications. [3] Due to the relatively small critical casting thickness of Fe-based metallic glasses (typically below 6 mm), industrial commercialization of Fe-based glass forming alloys are limited to applications such as anticorrosion or thermal-barrier coatings, applied, e.g., by spray coating methods [3,4] or laser cladding methods. [5,6] The often observed brittleness of Fe-based alloys has driven the development of Fe-based metallic glass compositions with improved ductility and glass-forming ability [7-9] and the development of bulk metallic glass matrix composites. [10-13] Previously, it was already demonstrated, that by, e.g., powder bed fusion (PBF), thermal spray additive manufacturing (TSAM), and direct energy deposition (DED) of FeCrMoCB a large variety of microstructures can be achieved: fully amorphous, dendrite-reinforced metal matrix composites, and fully crystalline. [14,15] Despite these developments, Fe-based metallic glasses have not found widespread use outside of coatings due to their exceptionally low fracture toughness in large glass-forming compositions and their reliance on volatile phosphorous in their tougher compositions. Tough Fe-based metallic glasses have been previously demonstrated in the FeNiBX system, but these are only accessible in the amorphous state through ultrarapid cooling. However, additive manufacturing of Fe-based metallic glasses will make it possible to realize bulk metallic glass parts from tough Fe-based alloys with low glass-forming ability. To avoid a time consuming, completely empirical process development for an additive manufacturing process, [15] numerical models of the fabrication process have nowadays become an essential instrument. Using the correct simulation models and precise thermophysical property data, the temperature distribution and history, fluid flows in the melt, porosity and other defect formation, as well as the formation of thermal stresses during the solidification in the additive manufacturing process can be predicted. [16] In a similar manner, this approach can also be used to improve simulation of other manufacturing processes, such as thermal spraying, laser cladding [17-20] and powder production by gas atomization [21,22] Consequently, process simulations based on precise thermophysical properties result in faster process development cycles. Such numerical simulations need not only to present the correct description of the involved physical phenomena, but they especially require the correct thermophysical properties of the alloy in the solid and liquid phases. While the relevant properties in the solid phase can be measured with commercial measurement equipment, container-based measurement methods for the liquid phase suff...

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Atomization simulation and preparation of 24CrNiMoY alloy steel powder using VIGA technology at high gas pressure

Cited by 62 publications

References 31 publications

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Numerical simulation and experiment for the ultrasonic field characteristics of ultrasonic standing wave atomization

Thermophysical Properties of an Fe_57.75Ni_19.25Mo₁₀C₅B₈ Glass‐Forming Alloy Measured in Microgravity

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Atomization simulation and preparation of 24CrNiMoY alloy steel powder using VIGA technology at high gas pressure

Cited by 62 publications

References 31 publications

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Centrifugal granulation behavior in metallic powder fabrication by plasma rotating electrode process

Numerical simulation and experiment for the ultrasonic field characteristics of ultrasonic standing wave atomization

Thermophysical Properties of an Fe57.75Ni19.25Mo10C5B8 Glass‐Forming Alloy Measured in Microgravity

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Thermophysical Properties of an Fe_57.75Ni_19.25Mo₁₀C₅B₈ Glass‐Forming Alloy Measured in Microgravity