Abstract
This study aims to enhance the production of metal powders using a novel approach that integrates computational fluid dynamics (CFD) with convergent-divergent (C-D) nozzles in wire arc spraying atomization (WASA). The primary objective is to investigate the influence of nozzle design on particle size distribution and production efficiency. Utilizing the ANSYS CFD Fluent program, simulations were conducted to analyze the effects of various parameters, including throat diameter and divergent angles, on gas dynamics and metal droplet behavior. The findings reveal that C-D nozzles facilitate the acceleration of gas flow to supersonic speeds, significantly improving the shear force acting on the molten metal, thereby promoting the fragmentation of droplets into smaller particles. Notably, the optimized nozzle configuration achieved a median particle size (D50) of 44.42 µm, suitable for additive manufacturing applications. The novelty of this work lies in its comprehensive simulation framework that allows for rapid virtual testing, potentially leading to significant improvements in the efficiency and quality of metal powder production processes. This research addresses critical gaps in the existing literature and provides a robust foundation for future studies in the field of metal powder manufacturing. Doi: 10.28991/HIJ-2024-05-03-02 Full Text: PDF
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