New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing
New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing
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DOI：
10.1016/j.addma.2024.104033
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发表时间：
2024-02
影响因子：
11
通讯作者：
A. Priyadarshi;Shazamin Bin Shahrani;Tomasz Choma;Lukasz Zrodowski;Ling Qin;C. L. Leung;Samuel J. Clark
中科院分区：
文献类型：
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作者：
A. Priyadarshi;Shazamin Bin Shahrani;Tomasz Choma;Lukasz Zrodowski;Ling Qin;C. L. Leung;Samuel J. Clark
超声雾化是用于生产增材制造的金属粉末的有前途的技术之一，其中精确控制颗粒尺寸和形态是必不可少的。在这项研究中，我们耦合的超声换能器与碳纤维板和雾化液滴和膜在不同的振动振幅。水，甘油，和纯铝熔体被用来研究雾化机制和所产生的液滴/粉末的特性，分别。高速光学和超快同步辐射X射线成像被用来研究原位超声雾化动力学，包括液体层/膜内的空腔的脉动和聚集，毛细管波的发展，以及液滴的形成。我们首次观察并捕获了静止液滴、薄膜和冲击液滴雾化过程中空化现象的发生。惯性空化事件与跨越相间边界的毛细波干涉，刺穿并打破边界以产生雾化雾。原位观察揭示了超声雾化的复杂动力学，并强调了空化事件在整个雾化过程中的关键作用。我们还进行了超声波雾化液态铝的实验，产生了完美的球形颗粒。我们的工作证明了如何在确保一致的颗粒形状和形态的同时定制粒度的重要加工策略，这是生产用于增材制造应用的高质量粉末的关键加工能力。
Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fiber plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminum melt were used to study the atomization mechanism and the resulting droplet/powder characteristics, respectively. High-speed optical and ultrafast synchrotron X-ray imaging were used to studyin situthe ultrasonic atomization dynamics, including pulsation and clustering of cavities inside the liquid layer/films, development of capillary waves, and formation of liquid droplets. For the first time, we observed and captured the occurrence of cavitation during the atomization of resting drops, films and impact droplets. The inertial cavitation events interfered with the capillary waves across the interphase boundary, puncturing and breaking the boundary to produce atomized mist. Thein situobservation revealed the intricate dynamics of ultrasonic atomization and underscored the pivotal role of cavitation events throughout the entire atomization process. We also conducted experiments on ultrasonic atomization of liquid aluminum, producing particles of perfectly spherical shape. The particle size tended to decrease with reduced vibration amplitude Our work has demonstrated the important processing strategies on how to tailor the particle size while ensuring consistent particle shape and morphology, which is the key processing capability for producing high quality powders for additive manufacturing applications.