Experimental and numerical investigations on molten metal atomization techniques – A critical review

Abstract

• All major types of atomizing techniques for molten metal are reviewed and compared. • Recent studies are tabulated including major results and operating conditions. • TAB and KHRT are common models for the numerical modeling of atomizers. • Hybrid geometries or combination of different techniques produce finer powders. • Centrifugal atomization is the most economical technique in industrial scale. Metal powders are highly practical in many applications such as solders, 3D printing, dental activities, etc. Atomization of molten metals and alloys is one of the common mechanisms for the production of powders. In this review, different techniques for the atomizing of molten metals including gas atomization, centrifugal atomization, water/oil atomization, and special atomization are compared and the advantages and disadvantages of each technique are discussed in detail. Furthermore, recent experimental and numerical investigations regarding different atomization techniques are reviewed in different operating conditions and materials for better understanding of the effects of different parameters on powder size. Hybrid atomization, which is the combination of different atomization techniques, is also represented. Finally, some special designs of atomizers for improving the size and quality of powders are introduced.