Numerical simulations of supersonic gas atomization of liquid metal droplets

Computational fluid dynamics simulations incorporating supersonic turbulent gas flow models and a droplet breakup model are performed to study supersonic gas atomization for producing micron-sized metal powder particles. Generally such atomization occurs in two stages: a primary breakup and a secondary breakup. Since the final droplet size is primarily determined by the secondary breakup, parent droplets of certain sizes (1 to 5 mm) typically resulting from the primary breakup are released at the corner of the nozzle and undergo the secondary breakup. A comparison of flow patterns with and without the introduction of a liquid melt clearly indicates that the mass loading effect is quite significant as a result of the gas-droplet interactions. The flow pattern change reasonably explains why the final droplets have a bimodal mass size distribution. The transient size changes of the droplets are well described by the behavior of the Weber number. The present results based on the 1 mm parent droplets best fit previous experimental results. Moreover, the effects of inlet gas pressure and temperature are investigated in an attempt to further reduce droplet size. (C) 2014 The Japan Society of Applied Physics