Numerical simulation of high-pressure gas atomization of two-phase flow: Effect of gas pressure on droplet size distribution

Nozzle clogging in vacuum induction melting gas atomisation: influence of gas pressure and melt orifice diameter coupling

“…Due to a large number of turbulent eddies near the recirculation zone below the delivery tube, the alloy melt film will be broken into many ligaments and small droplets by strong atomising gas. The inconsistent direction of turbulent eddies makes the alloy melt droplets disperse near the tip of the delivery tube [14]. Firstly, the atomisation state of the alloy melt is observed when the melt orifice diameter is 4 mm.…”

“…Continuous surface force (CSF) method [14] is used to model the surface tension force (body force), which only has non-zero values at the interface between gas and alloy melt. The surface tension force is defined as [24]: where is the local interface curvature, is the surface tension coefficient and represents the interface normal.…”

“…where T is the material temperature in Kelvin, E is the internal energy of the material in Joules, k eff is the effective thermal conductivity in W/(m•K), and S T is the viscous dissipation term, which was calculated from the average of the two-phase volumetric fraction analogous to the density calculation. Continuous surface force (CSF) method [14] is used to model the surface tension force (body force), which only has non-zero values at the interface between gas and alloy melt. The surface tension force is defined as [24]:…”

“…The simulation and experimental results showed that the gas velocity did not increase monotonically with the increase of pressure. Arachhilage et al [14] investigated the effect of gas pressure on the particle size distribution of metal droplets by VOF multiphase flow simulation method. This method realised the visualisation of the primary atomisation of metal melt flow.…”

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

“…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.…”