ATOMIZATION TECHNOLOGY

In recent years has turned to several advanced powder fabrication

techniques which fall under the general heading of atomization.
Atomization process operate at production rates as high as 400
kg/min. Prior to the development of atomization, powder chemistry
and shape characteristics could not be fully controlled.
Atomization involves the formation of powder from molten metal
using a spray of droplets. It is attractive because of the applicability to
several alloys and easy process control. Atomization relies upon fusion
based technology which provides control over melt purification and
alloy chemistry.
 GAS ATOMIZATION
The use of air, nitrogen, helium, or
argon as a fluid for breaking up a molten
metal stream provides an array of versatile
powder fabrication techniques. The liquid
metal stream is disintegrated by rapid gas
expansion out of a nozzle.
Classification of
Atomization

Horizontal Vertical Inert

Gas Atomization Gas Atomization
 Operating Variables / Parameters
of Gas Atomization Process
Gas atomization can be performed totally under inert
conditions, thereby maintaining the integrity of high alloy
feedstock. The particle shape is spherical with a fairly wide
size distribution. The gas atomization process has a large
number of operating variables, including :
a) gas type,
b) residual atmosphere,
c) melt temperature and viscosity as it enters the nozzle,
d) alloy type,
e) metal feed rate,
f) gas pressure,
g) gas feed rate and velocity,
h) nozzle geometry,
i) and gas temperature.
 The Main Advantage of
Gas Atomization
Those parameters are adjusted to
maintain process control and tailor the
powder characteristics for various uses.
The main advantage of gas atomization
is :
a) the product homogeneity,
b) and the good packing properties
available with the resulting spherical
powder.
Table 1. Example Atomization Parameters for the Production of a Nickel Superalloy Powder
 In gas atomization, the greater the energy input to the
metal, the finer the resulting powder. The gas metal
interaction at the nozzle exit has been studied using high
speed photography. The atomization physics are described
by the drawing shown as figure 3.

Figure 3. The formation of a metal powder by gas atomization involves the break-up
of the liquid stream by the rapidly expanding gas. Because of a suction pressure in the
gas expansion zone, the stream first forms into a thin hollow sheet, and subsequently
forms ligament, ellipsoids, and spheres.
 The liquid continues to respond to the surface
shear and acceleration forces from the gas as
illustrated in figure 4. The size reduction is limited
by the melt viscosity and temperature, and by the
response to the acceleration forces. Superheating
the melt above the liquidus decreases viscosity
the atomization solidification time.
The droplet shape sequence, with distance
from the nozzle, occurs as cylinder – cone – sheet
– ligament – sphere. Depending on the amount of
superheat and other variables, solidification may
produce any on of these shapes.

Schematic Diagram of
The Droplet Shape
 Figure 5, illustrates the change in the cumulative
particles size distribution for aluminum powders with
changes in the atomization pressure and melt
temperature (melting temperature is near 660°C).

Figure 5. Examples of cumulative particle size distributions for aluminum under

different atomization pressures and melt temperatures. The data illustrate the
production of smaller powders through increased energy delivery in the atomization
event.
Other Atomization Approaches

Vibrating wires

High speed rollers

Example
Spining crucibles

Melting explosion atomizer