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

气体雾化工艺是一种常用的生产金属粉末的方法，它是通过重力作用使熔体流快速破碎而产生的。熔体流动的破碎始于细丝的形成(一次雾化)，然后是进一步的破碎和球形液滴的形成(即二次破碎)。气体雾化工艺的有效性直接影响到粉末制造厂生产的粉末的粒度分布。用这种工艺生产的粉末用于关键的金属化应用，它们必须满足某些规格。能够模拟气雾化，特别是气体与熔体之间的相互作用区，对于优化工艺参数以满足要求的规格是一个有价值的进步。与领先的粉末制造商EutecticCanada Inc.合作，我们的目标是计算优化的雾化气体流量和熔融金属温度，以防止雾化过程中的熔融金属凝固，并重要地预测最终的粒度分布。在本项目中，将对多相流和换热进行计算流体动力学(CFD)模拟。我们期待这项研究的结果将使共晶加拿大公司在制造可控和可重复的金属粉末方面发挥更大的作用，这些粉末用于先进的添加剂制造工艺以及各种涂层工艺，如HVOF和HVAF。此外，航空航天、汽车和能源部门的终端用户将从该项目中受益，提高他们的竞争力，并为魁北克和加拿大的经济做出贡献。

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.