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Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation

Vacuum induction melting gas atomization (VIGA) has evolved as an important production technique of superalloy powders used in additive manufacturing. However, the development of powder preparation techniques is limited because the crushing process of gas-atomized metal melt is difficult to characte...

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Autores principales: Qing, Yongquan, Guo, Kuaikuai, Liu, Chen, Qin, Youyi, Zhan, Yu, Shuo, Shang, Wei, Yanpeng, Yu, Bo, Liu, Changsheng
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2022
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9102421/
https://www.ncbi.nlm.nih.gov/pubmed/35591362
http://dx.doi.org/10.3390/ma15093020
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author Qing, Yongquan
Guo, Kuaikuai
Liu, Chen
Qin, Youyi
Zhan, Yu
Shuo, Shang
Wei, Yanpeng
Yu, Bo
Liu, Changsheng
author_facet Qing, Yongquan
Guo, Kuaikuai
Liu, Chen
Qin, Youyi
Zhan, Yu
Shuo, Shang
Wei, Yanpeng
Yu, Bo
Liu, Changsheng
author_sort Qing, Yongquan
collection PubMed
description Vacuum induction melting gas atomization (VIGA) has evolved as an important production technique of superalloy powders used in additive manufacturing. However, the development of powder preparation techniques is limited because the crushing process of gas-atomized metal melt is difficult to characterize by conventional experimental methods. Herein, we report the application of computational fluid dynamics to simulate the breaking behavior of droplets in the process of preparing nickel-based superalloy powders by VIGA, as well as the results on the effect of gas pressure on the atomization process and powder particle size distribution of metal melt. In the process of primary atomization, the crushing morphology of superalloy melt shows an alternate transformation of umbrella shapes and inverted mushroom cloud shapes, and with the increase in atomization pressure, the disorder of the two-phase flow field increases, which is conducive to sufficient breakage of the melt. Most importantly, in the process of secondary atomization and with the increasing atomization pressure, the particle size distribution becomes narrower, the median particle diameter and average particle size decrease, and the decreasing trend of the particle size increases gradually. The simulation results are compliant with the performed nickel-based superalloy powder preparation tests. This study provides insight into the production and process optimization of superalloy powder prepared by the VIGA method.
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spelling pubmed-91024212022-05-14 Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation Qing, Yongquan Guo, Kuaikuai Liu, Chen Qin, Youyi Zhan, Yu Shuo, Shang Wei, Yanpeng Yu, Bo Liu, Changsheng Materials (Basel) Article Vacuum induction melting gas atomization (VIGA) has evolved as an important production technique of superalloy powders used in additive manufacturing. However, the development of powder preparation techniques is limited because the crushing process of gas-atomized metal melt is difficult to characterize by conventional experimental methods. Herein, we report the application of computational fluid dynamics to simulate the breaking behavior of droplets in the process of preparing nickel-based superalloy powders by VIGA, as well as the results on the effect of gas pressure on the atomization process and powder particle size distribution of metal melt. In the process of primary atomization, the crushing morphology of superalloy melt shows an alternate transformation of umbrella shapes and inverted mushroom cloud shapes, and with the increase in atomization pressure, the disorder of the two-phase flow field increases, which is conducive to sufficient breakage of the melt. Most importantly, in the process of secondary atomization and with the increasing atomization pressure, the particle size distribution becomes narrower, the median particle diameter and average particle size decrease, and the decreasing trend of the particle size increases gradually. The simulation results are compliant with the performed nickel-based superalloy powder preparation tests. This study provides insight into the production and process optimization of superalloy powder prepared by the VIGA method. MDPI 2022-04-21 /pmc/articles/PMC9102421/ /pubmed/35591362 http://dx.doi.org/10.3390/ma15093020 Text en © 2022 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Qing, Yongquan
Guo, Kuaikuai
Liu, Chen
Qin, Youyi
Zhan, Yu
Shuo, Shang
Wei, Yanpeng
Yu, Bo
Liu, Changsheng
Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title_full Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title_fullStr Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title_full_unstemmed Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title_short Impact of Atomization Pressure on the Particle Size of Nickel-Based Superalloy Powders by Numerical Simulation
title_sort impact of atomization pressure on the particle size of nickel-based superalloy powders by numerical simulation
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9102421/
https://www.ncbi.nlm.nih.gov/pubmed/35591362
http://dx.doi.org/10.3390/ma15093020
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