Numerical Simulation of Gas atomization in Close-C Eutectic Canada Inc.

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Gas atomization process is commonly used to produce metallic powders by rapid fragmentation of the flow ofmelt stream falling due to gravitational force. Fragmentation of melt stream starts with the formation ofligaments (primary atomization) followed by further breakup and the formation of spherical droplets (i.e.secondary breakup). The effectiveness of gas atomization process directly influences the powder sizedistribution produced in a powder manufacturing plant. Powders produced with this process are being used forcritical metallization applications and they must meet certain specifications. The ability to simulate the gasatomization particularly the zone of interaction between gas and melt stream is a valuable advancement for theoptimization of process parameters in order to meet the required specifications. In collaboration with EutecticCanada Inc., a leading powder manufacturer, we are aiming to calculate the optimized atomizing gas flow andmolten metal temperature in order to prevent the molten metal solidification during the atomization processand importantly predict the final particle size distribution. In this project, a Computational Fluid Dynamics(CFD) simulation of multiphase flow and heat transfer will be performed. We are expecting that the results ofthis study will allow Eutectic Canada Inc. to enhance its role in the fabrication of controllable and repeatablemetallic powders used in advanced additive manufacturing process as well as various coating processes such asHVOF and HVAF. Moreover, end users from aerospace, automotive, and energy sectors will benefit from theproject by enhancing their competitiveness and by contributing to the economy of Quebec and Canada.