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Ladle Nozzle Clogging in Vacuum Induction Melting Gas Atomization: Influence of the Melt Viscosity

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Abstract

During the production of fine metal powder using vacuum induction melting gas atomization (VIGA) technology, the problem of nozzle clogging is often encountered. The viscosity of melt is one of the key factors causing the clogging of nozzle. To visualize the mechanism of the clogging of nozzle, the volume of fluid (VOF) model combined with large eddy turbulence model was used to simulate the nozzle-clogging process of an alloy melt in the primary atomization zone. The results show that, with the increase of viscosity, the flow rate of the melt in the delivery-tube decreased, the heat dissipation of the melt increased, and the crushing resistance increased. In addition, the melt flow that was not broken in time hanged at the tip of the delivery-tube, and resulted in nozzle-clogging. The simulation results were also verified by the gas atomization experiments. When the viscosity of the melt was 5.24–5.45 mPa s, the atomization process was continuous, the particle size distribution was uniform, and the yield of fine powder was high. However, when the viscosity continued to decrease, a larger mass flow rate had the opposite effect, and the powder particles became coarser. This research is of guiding significance for understanding the continuity of atomization process of VIGA technology.

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Conflict of interest

We declare that we have no financial and personal relationships with other people or organizations that can inappropriately influence our work, there is no professional or other personal interest of any nature or kind in any product, service and company that could be construed as influencing the position presented in, or the review of the manuscript entitled. On behalf of all authors, I declare that there is no conflict of interest.

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Authors and Affiliations

  1. Institute of Special Ceramics and Powder Metallurgy, University of Science & Technology Beijing, 30 Xueyuan Road, Haidian District, Beijing, 100083, China

    Junfeng Wang, Min Xia & Jialun Wu

  2. Institute of Special Ceramics and Powder Metallurgy, University of Science & Technology Beijing, Beijing, China

    Changchun Ge

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  1. Junfeng Wang
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  2. Min Xia
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  3. Jialun Wu
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Correspondence to Min Xia.

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Wang, J., Xia, M., Wu, J. et al. Ladle Nozzle Clogging in Vacuum Induction Melting Gas Atomization: Influence of the Melt Viscosity. Metall Mater Trans B 53, 2386–2397 (2022). https://doi.org/10.1007/s11663-022-02537-y

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