Gas Atomization of Aluminium Melts: Comparison of Analytical Models

Abstract: A number of analytical models predicting the size distribution of particles during atomization of Al-based alloys by N₂, He and Ar gases were compared. Simulations of liquid break up in a close coupled atomizer revealed that the finer particles are located near the center of the spray cone. Increasing gas injection pressures led to an overall reduction of particle diameters and caused a migration of the larger powder particles towards the outer boundary of the flow. At sufficiently high gas pressures the spray became monodisperse. The models also indicated that there is a minimum achievable mean diameter for any melt/gas system.