Visualization of Atomization Gas Flow and Melt Break-up Effects in Response to Nozzle Design

Both powder particle size control and efficient use of gas flow energy are highly prized goals for gas atomization of metal and alloy powder to minimize off-size powder inventory (or 'reverb') and excessive gas consumption. Recent progress in the design of close-coupled gas atomization nozzles and the water model simulation of melt feed tubes were coupled with previous results from several types of gas flow characterization methods, e.g., aspiration measurements and gas flow visualization, to make progress toward these goals. Size distribution analysis and high speed video recordings of gas atomization reaction synthesis (GARS) experiments on special ferritic stainless steel alloy powders with an Ar+O{sub 2} gas mixture were performed to investigate the operating mechanisms and possible advantages of several melt flow tube modifications with one specific gas atomization nozzle. In this study, close-coupled gas atomization under closed wake gas flow conditions was demonstrated to produce large yields of ultrafine (dia.<20 {mu}m) powders (up to 32%) with moderate standard deviations (1.62 to 1.99). The increased yield of fine powders is consistent with the dual atomization mechanisms of closed wake gas flow patterns in the near-field of the melt orifice. Enhanced size control by stabilized pre-filming of the melt with amore » slotted trumpet bell pour tube was not clearly demonstrated in the current experiments, perhaps confounded by the influence of the melt oxidation reaction that occurred simultaneously with the atomization process. For this GARS variation of close-coupled gas atomization, it may be best to utilize the straight cylindrical pour tube and closed wake operation of an atomization nozzle with higher gas mass flow to promote the maximum yields of ultrafine powders that are preferred for the oxide dispersion strengthened alloys made from these powders.« less