Effect of Electrode Induction Melting Gas Atomization Process on Fine Powder Yields: Continuous Metal Melt Flow

Electrode induction melting gas atomization (EIGA) is a newly developed method for preparing ultra-clean metal powders, and is a completely crucible-free melting and atomization process. Based on conducted several atomization experiments, we found that the fine powder yields obtained during the EIGA process were greatly affected by the status of metal melt flow. While, continuous metal melt flow was beneficial for the yield of fine powders, it was in conflict with the principle described for the vacuum induction melting inert gas atomization (VIGA) process. To understand the critical role of continuous metal melt flow in the EIGA process, a computational fluid dynamics (CFD) approach was developed to simulate the gas atomization process. The D50 particle size of powder prepared by atomization under continuous liquid metal flow was about 70 μm, while that obtained by atomization under non-continuous liquid metal flow was about 100 μm. The diameter distribution results of numerical simulations agreed well with the experimental measurements, which demonstrated the accuracy of our simulation method. This study provides theoretical support for understanding the critical role of continuous metal melt flow and improving fine powder yields in the EIGA process.