The Numerical and Experimental Investigation of Particle Size Distribution Produced by an Electrical Discharge Process

The vague influence of thermal action of electrical discharge on size distribution of metallic powders hinders the adjustability of powder quality. Due to the small gap, short discharge on-time, uncertain discharge point, and strong light interference, direct observation of preparation is difficult to carry out. Herein, the multi-physics coupling finite element method (FEM) was applied to numerically investigate the relationship between size distribution and thermal action. Through modeling of thermal transformation and heat distribution on the surface of electrode, temperature of the electrode is found to be decided by the latent heat and the distribution of heat point obeys the normal distribution, which corresponds with experimental results. Finally, the vapor film to droplet fragmentation theory was proposed to explain the phenomenon of normal distribution. The research results provide theoretical support for the preparation of metallic powder by electrical discharge, and also play a guiding role in optimizing the process parameters in the actual preparation process to tune the size distribution.