Precise control of atomization initial stage to address nozzle clogging issue in the vacuum induction-melting gas atomization process

Vacuum induction-melting gas atomization (VIGA) is considered a widely applied method to prepare metal powders. However, the nozzle clogging problem in the VIGA process seriously affects the continuity of production and greatly increases the economic and time costs. In the atomization initial stage, the existence of unsteady state atomization mainly results in the nozzle clogging challenge. To understand the formation mechanism of nozzle clogging, a computational fluid dynamics (CFD) model was established to simulate the influence of unsteady state atomization sequence on the primary atomization of alloy melt. Typically, there are two kinds of sequence including starting the gas before pooling the alloy (namely, GA) and pouring the alloy before opening the gas (AG). The movement trajectory of the alloy melt droplet at the end of the delivery-tube was clarified. Based on CFD simulation, the atomization sequence of AG and GA was precisely controlled in the atomization pressure range of 2.5 MPa, 3.5 MPa, and 4.5 MPa to address the nozzle clogging issue. In the GA process, relatively finer powder was obtained at 3.5 MPa without nozzle clogging occurring. In contrast, the AG process greatly reduces the probability of nozzle clogging at 2.5-4.5 MPa, the final prepared powder is coarser. The predicted results of industrial experiments and numerical simulations are consistent. This study provides theoretical support for understanding the formation mechanism of nozzle clogging during the VIGA process.