Multi-physics coupling simulation of electrode induction melting gas atomization for advanced titanium alloys powder preparation

A numerical modeling method is proposed for the melting process of Titanium metals of Titanium alloys powder preparation used for 3D printing. The melting process simulation, which involves the tight coupling between electromagnetic field, thermal field and fluid flow as well as deformation associated during the melting process, is conducted by adopting the finite element method. A two-way coupling strategy is used to include the interactions between these fields by incorporating the material properties dependent on temperature and the coupling terms. In addition, heat radiation and phase change are also considered in this paper. The arbitrary Lagrangian–Eulerian formulation is exploited to model the deformation of Titanium metal during the melting process. The distribution of electromagnetic flux density, eddy current density, temperature, and fluid flow velocity at different time can be determined by utilizing this numerical method. In a word, the method proposed in this paper provides a general way to predict the melting process of electrode induction melting gas atomization (EIGA) dynamically, and it also could be used as a reference for the design and optimization of EIGA.