Gas-atomized pure metal or alloy powders are widely used as raw material in the preparation of high performance materials by powder metallurgy route（compaction and sintering）. However, cold compactibility of gas-ato...Gas-atomized pure metal or alloy powders are widely used as raw material in the preparation of high performance materials by powder metallurgy route（compaction and sintering）. However, cold compactibility of gas-atomized Al-Si alloy powder is inhibited due to the high strength as a result of the refined Si phases and the supersaturated Al matrix. The effect of annealing on improving the compactibility of Al-Si alloy powder was studied. The densification was investigated by the HECKEL compaction equation in terms of deformation capacity. Moreover, the microstructures and bending fracture surfaces of the green compacts were examined to clarify the densification behavior. The results show that a maximum relative density of 96.1% is obtained when the powder is annealed at 400 °C. The deformation capacity is significantly improved by annealing treatment due to the softening of Al matrix, precipitation of supersaturated Si phases, dissolution of needle-like eutectic phase, and spheroidization of Si phases.展开更多
A comparative study on the performance of gas atomized(GA)and rotating-disk atomized(RDA)aluminum alloy powders produced on industrial scale for laser directed energy deposition(L-DED)process was carried out.The powde...A comparative study on the performance of gas atomized(GA)and rotating-disk atomized(RDA)aluminum alloy powders produced on industrial scale for laser directed energy deposition(L-DED)process was carried out.The powder characteristics,the printing process window,and the quality,microstructure,and mechanical properties of printed parts were taken into account for comparison and discussion.The results demonstrate that the RDA powder is superior to the GA powder in terms of sphericity,surface quality,internal defects,flowability,and apparent density,together with a larger printing process window during the L-DED parts fabrication.Besides,the resultant parts from the RDA powder have higher dimensional accuracy,lower internal defects,more uniform and finer microstructure,and more favorable mechanical properties than those from the GA powder.展开更多
The specific Fe-based alloy for direct metal forming was designed and prepared under multi-layer cladding condition.The powder was designed for getting the better formability,toughness and hardness.The experiment used...The specific Fe-based alloy for direct metal forming was designed and prepared under multi-layer cladding condition.The powder was designed for getting the better formability,toughness and hardness.The experiment used KR6 robot and NW5000 digital power supply as the hardware environment.Microstructure and hardness of the layer formed by different powder were analyzed by using X-ray diffraction (XRD) and Transmission Electron Microscope (TEM).The result shows that thermal expansion coefficient correlated with processing formability is not linearity.Hardness of the layers is correlated to elements phase of the coatings was formed by γ(FeNi) and α(FeCrNi),and a little Cr23C6、Fe3Si and MoO2.展开更多
Powder extrusion, which is based on the superplastic behavior of Zn-22%A1 eutectoid alloy, was proposed to reduce the forming load and promises to provide fine microstructures in the manufacture of miniature helical g...Powder extrusion, which is based on the superplastic behavior of Zn-22%A1 eutectoid alloy, was proposed to reduce the forming load and promises to provide fine microstructures in the manufacture of miniature helical gears. The specifications of the helical gears were as follows： module, 0.3; number of teeth, 12; and helix angle, 15°. Compacted powders were consolidated by sintering and solution heat treatment. The consolidated billets consisted of lamellar and fine-grained microstructures. Extrusion experiments were carried out under the following conditions： temperature, 250 ℃; strain rates, 2.36× 10-3 s^-1 and 1.18× 10^-1 s-1. The mechanical properties of the extruded helical gears were investigated by measurement of the Vickers hardness and extrusion load, and by scanning electron microscopy.展开更多
Water atomized Fe Ni Mo steel powder, was utilized as base powder for designing powder mixtures for warm pressing. The warm pressing and sintering behaviours of the powder mixtures were studied. The results show that,...Water atomized Fe Ni Mo steel powder, was utilized as base powder for designing powder mixtures for warm pressing. The warm pressing and sintering behaviours of the powder mixtures were studied. The results show that, compared with the pressing at room temperature, the green density gain by warm pressing is within a range of 0.10 0.19 g/cm 3 and reduction in spring back is 30% 40% of the ambient, and maximum green density of 7.32 g/cm 3 at 735 MPa is obtained as the graphite mass fraction is 0.8%. It was found that sintered densities of the compacts were reduced slightly due to releasing of elastic stress stored in the compacts during sintering. The warm pressing of steel powders gives evidence for substituting the traditional double pressing and double sintering process.展开更多
Copper, iron and cobalt based pre-alloyed powders for diamond tools were prepared by ultrahigh pressure water atomization（UPWA） process. Pre-alloyed powders prepared by different processes including UPWA, convention...Copper, iron and cobalt based pre-alloyed powders for diamond tools were prepared by ultrahigh pressure water atomization（UPWA） process. Pre-alloyed powders prepared by different processes including UPWA, conventional water atomization （CWA） and elemental metal mechanical mixing （EMMM） were sintered to segments and then compared in mechanical properties, holding force between matrix and diamond, fracture morphology of blank and sintering diamond section containing matrix. The results showed that the pre-alloyed powder prepared by UPWA exhibits the best mechanical properties including the relative density, the hardness and the bending strength of matrix sinteredsegment. Sintered segments fractography of UPWA pre-alloyed powder indicatesmechanical mosaic strength and chemical bonding force between the pre-alloyed powder and the diamond, leading to the great increase in the holding force between matrix and diamond. The mechanical performance andthe service life of diamond tools were greatly improved by UPWA pre-alloyed powders.展开更多
SiC magnetic abrasive is used to polish surfaces of precise, complex parts which are hard, brittle and highly corrosion-resistant in magnetic abrasive finishing（MAF）. Various techniques are employed to produce this ...SiC magnetic abrasive is used to polish surfaces of precise, complex parts which are hard, brittle and highly corrosion-resistant in magnetic abrasive finishing（MAF）. Various techniques are employed to produce this magnetic abrasive, but few can meet production demands because they are usually time-consuming, complex with high cost, and the magnetic abrasives made by these techniques have irregular shape and low bonding strength that result in low processing efficiency and shorter service life. Therefore, an attempt is made by combining gas atomization and rapid solidification to fabricate a new iron-based SiC spherical composite magnetic abrasive. The experimental system to prepare this new magnetic abrasive is constructed according to the characteristics of gas atomization and rapid solidification process and the performance requirements of magnetic abrasive. The new iron-based SiC spherical composite magnetic abrasive is prepared successfully when the machining parameters and the composition proportion of the raw materials are controlled properly. Its morphology, microstructure, phase composition are characterized by scanning electron microscope（SEM） and X-ray diffraction（XRD） analysis. The MAF tests on plate of mold steel S136 are carried out without grinding lubricant to assess the finishing performance and service life of this new SiC magnetic abrasive. The surface roughness（Ra） of the plate worked is rapidly reduced to 0.051 μm from an initial value of 0.372 μm within 5 min. The MAF test is carried on to find that the service life of this new SiC magnetic abrasive reaches to 155 min. The results indicate that this process presented is feasible to prepare the new SiC magnetic abrasive; and compared with previous magnetic abrasives, the new SiC spherical composite magnetic abrasive has excellent finishing performance, high processing efficiency and longer service life. The presented method to fabricate magnetic abrasive through gas atomization and rapid solidification presented can significantly improve the finishing performance and service life of magnetic abrasive, and provide a more practical approach for large-scale industrial production of magnetic abrasive.展开更多
A self-developed double-nozzle gas atomization technique was used to produce AlSi10Mg powder.Effects of delivery tube diameter,gas pressure,and melt superheat on powder characteristics were investigated.The concepts o...A self-developed double-nozzle gas atomization technique was used to produce AlSi10Mg powder.Effects of delivery tube diameter,gas pressure,and melt superheat on powder characteristics were investigated.The concepts of bluntness and outgrowth were introduced to analyze powder sphericity and satellite index quantitatively.The results showed that the median diameters of all atomized powders ranged from 25 to 33μm.The highest yield rate(72.13%)of fine powder(<50μm)was obtained at a superheat of 350 K.The powder size decreased with increasing melt superheat but increased with increasing delivery tube diameter.Powders with bluntness values between 96%and 98%accounted for over 60%.The outgrowth values demonstrated that 70%-85%of all powders did not contain satellite particles,with few powders adhered two or three particles.Not only Al and Si phases were present but also a metastable Al9Si phase was detected.展开更多
Gas atomization was usually regarded as a good method for producing the spherical or approximate spherical powders. We found a lot of non-spherical powders in production processes, especially in larger particle size d...Gas atomization was usually regarded as a good method for producing the spherical or approximate spherical powders. We found a lot of non-spherical powders in production processes, especially in larger particle size distribution area. The causes of producing non-spherical powders are explained and some analyses are done in order to find a better condition of producing spherical powders in this paper. The following morphologies were obtained by atomized Fe50 Co50 and pure iron and investigated by scanning electron microscopy （SEM）.展开更多
Gas atomization is now an important production technique for Fe-based amorphous alloy powders used in additive manufacturing,particularly selective laser melting,fabricating large-sized Fe-based bulk metallic glasses....Gas atomization is now an important production technique for Fe-based amorphous alloy powders used in additive manufacturing,particularly selective laser melting,fabricating large-sized Fe-based bulk metallic glasses.Using the realizable k-εmodel and discrete phase model theory,the flow dynamics of the gas phase and gas-melt two-phase flow felds in the close-wake condition were investigated to establish the correlation between high gas pressure and powder particle characteristics.The locations of the recirculation zones and the shapes of Mach disks were analyzed in detail for the type of discrete-jet closed-coupled gas atomization nozzle.In the gas-phase flow feld,the vortexes,closed to the Mach disk,are found to be a new deceleration method.In the two-phase flow feld,the shape of Mach disk changes from“S”-shape to“Z”-shape under the impact of the droplet flow.As predicted by the wave model,with the elevation of gas pressure,the size of the particle is found to gradually decrease and its distribution becomes more concentrated.Simulation results were compliant with the Fe-based amorphous alloy powder preparation tests.This study deepens the understanding of the gas pressure impacting particle features via gas atomization,and contributes to technological applications.展开更多
The paper aims at modeling and simulating the atomization process of the close-coupled ring-hole nozzle in vacuum induction gas atomization(VIGA)for metallic powder production.First of all,the primary atomization of t...The paper aims at modeling and simulating the atomization process of the close-coupled ring-hole nozzle in vacuum induction gas atomization(VIGA)for metallic powder production.First of all,the primary atomization of the ring-hole nozzle is simulated by the volume of fluid(VOF)coupled large eddy simulation(LES)model.To simulate the secondary atomization process,we use the method of selecting the droplet sub-model and the VOF model.The results show that the ring-hole nozzle forms a gas recirculation zone at the bottom of the delivery tube,which is the main reason for the formation of an annular liquid film during the primary atomization.In addition,the primary atomization process of the ring-hole nozzle consists of three stages:the formation of the serrated liquid film tip,the appearance and shedding of the ligaments,and the fragmentation of ligaments.At the same time,the primary atomization mainly forms spherical droplets and long droplets,but only the long droplets can be reserved and proceed to the secondary atomization.Moreover,increasing the number of ring holes from 18 to 30,the mass median diameter(MMD,d_(50))of the primary atomized droplets decreases first and then increases,which is mainly due to the change of the thickness of the melt film.Moreover,the secondary atomization of the ring-hole nozzles is mainly in bag breakup mode and multimode breakup model,and bag breakup will result in the formation of hollow powder,which can be avoided by increasing the gas velocity.展开更多
Based on volume of fluid(VoF)interface capturing method and shear-stress transport(SST)k-ω turbulence model,numerical simulation was performed to reveal the flow mechanism of metal melts in melt delivery nozzle(MDN)d...Based on volume of fluid(VoF)interface capturing method and shear-stress transport(SST)k-ω turbulence model,numerical simulation was performed to reveal the flow mechanism of metal melts in melt delivery nozzle(MDN)during gas atomization(GA)process.The experimental validation indicated that the numerical models could give a reasonable prediction on the melt flow process in the MDN.With the decrease of the MDN inner-diameter,the melt flow resistance increased for both molten aluminum and iron,especially achieving an order of 10^(2) kPa in the case of the MDN inner-diameter≤1 mm.Based on the conventional GA process,the positive pressure was imposed on the viscous aluminum alloy melt to overcome its flow resistance in the MDN,thus producing powders under different MDN inner-diameters.When the MDN inner-diameter was reduced from 4 to 2 mm,the yield of fine powder(<150μm)soared from 54.7%to 94.2%.The surface quality of powders has also been improved when using a smaller inner-diameter MDN.展开更多
The influence of cooling rate on the microstructure of Al0.6CoCrFeNi high entropy alloy（HEA） powders was investigated. The spherical HEA powders（D50≈78.65 μm） were prepared by high pressure gas atomization. The ...The influence of cooling rate on the microstructure of Al0.6CoCrFeNi high entropy alloy（HEA） powders was investigated. The spherical HEA powders（D50≈78.65 μm） were prepared by high pressure gas atomization. The different cooling rates were achieved by adjusting the powder diameter. Based on the solidification model, the relationship between the cooling rate and the powder diameter was developed. The FCC phase gradually disappears as particle size decreases. Further analysis reveals that the phase structure gradually changes from FCC＋BCC dual-phase to a single BCC phase with the increase of the cooling rate. The microstructure evolves from planar crystal to equiaxed grain with the cooling rate increasing from 3.19×10^4 to 1.11×10^6 K/s.展开更多
The almost completely dense copper was prepared by ultrafine copper powder prepared with both methods of electrolysis and novel water-gas atomization through cold isostatic pressing(CIP)and sintering under atmospheric...The almost completely dense copper was prepared by ultrafine copper powder prepared with both methods of electrolysis and novel water-gas atomization through cold isostatic pressing(CIP)and sintering under atmospheric hydrogen.Fine copper powder possesses the higher sintering driving force,thereby promoting shrinkage and densification during the sintering process.The grain size of sintered samples by electrolytic copper powder is smaller than that prepared by the atomized copper powder,and the twin crystals are particularly prone to forming in the former sintered microstructure due to the raw powder with low oxygen content and high residual stress originating from the CIP process.The relative density of samples by electrolytic and atomized powder at 1000℃ sintering temperature achieves 99.3%and 97.4%,respectively,significantly higher than that of the powder metallurgy copper parts reported in the literature.Correspondingly,the ultimate tensile strength and yield strength of samples by both kinds of copper powder are approximately similar,while the elongation of the sintered sample by the electrolytic powder(60%)is apparently higher than the atomized powder(44%).The superior performance of samples fabricated by electrolytic powder is inferred from the full density and low oxygen level for there is no cuprous oxide in the grain boundaries.展开更多
17-4PH stainless steel powders were prepared using a supersonic nozzle in a close-coupled gas atomization system. The characteristics of powder particles were carried out by means of a laser particle size analyzer, sc...17-4PH stainless steel powders were prepared using a supersonic nozzle in a close-coupled gas atomization system. The characteristics of powder particles were carried out by means of a laser particle size analyzer, scanning electron microscopy （SEM）, and the X-ray diffraction （XRD） technique. The results show that the mass median particle diameter is about 19.15 prn. Three main types of surface microstructures are observed in the powders： well-developed dendrite, cellular, and cellular dendrite structure. The XRD measurements show that, as the particle size decreases, the amount of fcc phase gradually decreases and that of bcc phase increases. The cooling rate is inversely related to the particle size, i.e., it decreases with an increase in particle size.展开更多
A novel technique for YAG:Ln(Ln=Eu,Ce) phosphor powder synthesis with a nanocrystalline structure was developed.Nanocrystalline YAG:Ln powder was prepared by an ultrasonic atomization and co-precipitation method using...A novel technique for YAG:Ln(Ln=Eu,Ce) phosphor powder synthesis with a nanocrystalline structure was developed.Nanocrystalline YAG:Ln powder was prepared by an ultrasonic atomization and co-precipitation method using a mixture solution of ammonium hydroxide(NH3·H2O) and ammonium hydrogen carbonate(NH4HCO3) as precipitant.The as-prepared nano-powders were characterized by X-ray diffraction(XRD),scanning electron microscopy(SEM),and fluorescence spectrometer.The obtained phosphor powders were homogenous and in size of 50-70 nm.The results demonstrated that by using ultrasonic atomization and co-precipitation process,we could synthesize a good quality YAG:Ln(Ln=Eu,Ce) phosphor powder that had many potential applications.展开更多
Al-20Sn-1Cu powders were prepared by gas atomization in an argon atmosphere with atomizing pressures of 1.1 and 1.6 MPa. The characteristics of the powders are determined by means of dry sieving, scanning electron mic...Al-20Sn-1Cu powders were prepared by gas atomization in an argon atmosphere with atomizing pressures of 1.1 and 1.6 MPa. The characteristics of the powders are determined by means of dry sieving, scanning electron microscopy （SEM）, optical microscopy （OM）, and X-ray diffractometry （XRD）. The results show that the powders exhibit a bimodal size distribution and a higher gas pressure results in a broad size distribution. All particles in both cases are spherical or nearly spherical and satellites form on the surface of coarse particles. Dendritic and cellular structures coexist in the particle. With decreasing particle diameter, the secondary dendrite arm spacing （SDAS） decreases and the cooling rate increases. The particles processed under high gas atomization pressure （1.6 MPa） exhibit a lower SDAS value and a higher cooling rate than those of the same size under low gas atomization pressure （1.1 MPa）. The XRD results show that the Sn content increases with decreasing particle size.展开更多
Super-clean and super-spherical FGH4095 superalloy powder is produced by the ceramic-free electrode inductionmelt inert gas atomization（EIGA） technique.A continuous and steady-state liquid metal flow is achieved at ...Super-clean and super-spherical FGH4095 superalloy powder is produced by the ceramic-free electrode inductionmelt inert gas atomization（EIGA） technique.A continuous and steady-state liquid metal flow is achieved at high-frequency（350 k Hz） alternating current and high electric power（100 k W）.The superalloy is immersed in a high-frequency induction coil,and the liquid metal falling into a supersonic nozzle is atomized by an Ar gas of high kinetic gas energy.Numerical calculations are performed to optimize the structure parameters for the nozzle tip.The undesired oxidation reaction of alloying elements starts at 1000℃ with the reaction originating from the active sites on the powder surfaces,leading to the formation of oxides,MexOy.The role of active sites and kinetic factors associated with the diffusion of oxygen present in the atomization gas streams are also examined.The observed results reveal that the oxidation process occurring at the surface of the produced powders gradually moves toward the core,and that there exists a clear interface between the product layer and the reactant.The present study lays a theoretical foundation for controlling the oxidation of nickel-based superalloy powders from the powder process step.展开更多
基金Project(CXZZ20140506150310438) supported by the Science and Technology Program of Shenzhen,ChinaProject(2017GK2261) supported by the Science and Technology Program of Hunan Province,China
文摘Gas-atomized pure metal or alloy powders are widely used as raw material in the preparation of high performance materials by powder metallurgy route（compaction and sintering）. However, cold compactibility of gas-atomized Al-Si alloy powder is inhibited due to the high strength as a result of the refined Si phases and the supersaturated Al matrix. The effect of annealing on improving the compactibility of Al-Si alloy powder was studied. The densification was investigated by the HECKEL compaction equation in terms of deformation capacity. Moreover, the microstructures and bending fracture surfaces of the green compacts were examined to clarify the densification behavior. The results show that a maximum relative density of 96.1% is obtained when the powder is annealed at 400 °C. The deformation capacity is significantly improved by annealing treatment due to the softening of Al matrix, precipitation of supersaturated Si phases, dissolution of needle-like eutectic phase, and spheroidization of Si phases.
基金supported by the National Natural Science Foundation of China(No.52074157)Department of Education of Guangdong Province,China(No.2023KTSCX121)Shenzhen Science and Technology Programs,China(Nos.JSGG20210802154210032,JCYJ20210324104608023,JSGG20180508152608855)。
文摘A comparative study on the performance of gas atomized(GA)and rotating-disk atomized(RDA)aluminum alloy powders produced on industrial scale for laser directed energy deposition(L-DED)process was carried out.The powder characteristics,the printing process window,and the quality,microstructure,and mechanical properties of printed parts were taken into account for comparison and discussion.The results demonstrate that the RDA powder is superior to the GA powder in terms of sphericity,surface quality,internal defects,flowability,and apparent density,together with a larger printing process window during the L-DED parts fabrication.Besides,the resultant parts from the RDA powder have higher dimensional accuracy,lower internal defects,more uniform and finer microstructure,and more favorable mechanical properties than those from the GA powder.
文摘The specific Fe-based alloy for direct metal forming was designed and prepared under multi-layer cladding condition.The powder was designed for getting the better formability,toughness and hardness.The experiment used KR6 robot and NW5000 digital power supply as the hardware environment.Microstructure and hardness of the layer formed by different powder were analyzed by using X-ray diffraction (XRD) and Transmission Electron Microscope (TEM).The result shows that thermal expansion coefficient correlated with processing formability is not linearity.Hardness of the layers is correlated to elements phase of the coatings was formed by γ(FeNi) and α(FeCrNi),and a little Cr23C6、Fe3Si and MoO2.
基金Project (2010-0008-277) supported by the NCRC (National Core Research Center) Program through the National Research Foundation of Korea,funded by the Ministry of Education,Science,and TechnologyProject (NRF-2009-K20601000004-09E0100-00410) supported by PNU-IFAM JRC
文摘Powder extrusion, which is based on the superplastic behavior of Zn-22%A1 eutectoid alloy, was proposed to reduce the forming load and promises to provide fine microstructures in the manufacture of miniature helical gears. The specifications of the helical gears were as follows： module, 0.3; number of teeth, 12; and helix angle, 15°. Compacted powders were consolidated by sintering and solution heat treatment. The consolidated billets consisted of lamellar and fine-grained microstructures. Extrusion experiments were carried out under the following conditions： temperature, 250 ℃; strain rates, 2.36× 10-3 s^-1 and 1.18× 10^-1 s-1. The mechanical properties of the extruded helical gears were investigated by measurement of the Vickers hardness and extrusion load, and by scanning electron microscopy.
文摘Water atomized Fe Ni Mo steel powder, was utilized as base powder for designing powder mixtures for warm pressing. The warm pressing and sintering behaviours of the powder mixtures were studied. The results show that, compared with the pressing at room temperature, the green density gain by warm pressing is within a range of 0.10 0.19 g/cm 3 and reduction in spring back is 30% 40% of the ambient, and maximum green density of 7.32 g/cm 3 at 735 MPa is obtained as the graphite mass fraction is 0.8%. It was found that sintered densities of the compacts were reduced slightly due to releasing of elastic stress stored in the compacts during sintering. The warm pressing of steel powders gives evidence for substituting the traditional double pressing and double sintering process.
基金Projects(2010SK3172,2015JC3005)supported by the Key Program of Science and Technology Project of Hunan Province,China
文摘Copper, iron and cobalt based pre-alloyed powders for diamond tools were prepared by ultrahigh pressure water atomization（UPWA） process. Pre-alloyed powders prepared by different processes including UPWA, conventional water atomization （CWA） and elemental metal mechanical mixing （EMMM） were sintered to segments and then compared in mechanical properties, holding force between matrix and diamond, fracture morphology of blank and sintering diamond section containing matrix. The results showed that the pre-alloyed powder prepared by UPWA exhibits the best mechanical properties including the relative density, the hardness and the bending strength of matrix sinteredsegment. Sintered segments fractography of UPWA pre-alloyed powder indicatesmechanical mosaic strength and chemical bonding force between the pre-alloyed powder and the diamond, leading to the great increase in the holding force between matrix and diamond. The mechanical performance andthe service life of diamond tools were greatly improved by UPWA pre-alloyed powders.
基金supported by National Natural Science Foundation of China(Grant No. 50775133)
文摘SiC magnetic abrasive is used to polish surfaces of precise, complex parts which are hard, brittle and highly corrosion-resistant in magnetic abrasive finishing（MAF）. Various techniques are employed to produce this magnetic abrasive, but few can meet production demands because they are usually time-consuming, complex with high cost, and the magnetic abrasives made by these techniques have irregular shape and low bonding strength that result in low processing efficiency and shorter service life. Therefore, an attempt is made by combining gas atomization and rapid solidification to fabricate a new iron-based SiC spherical composite magnetic abrasive. The experimental system to prepare this new magnetic abrasive is constructed according to the characteristics of gas atomization and rapid solidification process and the performance requirements of magnetic abrasive. The new iron-based SiC spherical composite magnetic abrasive is prepared successfully when the machining parameters and the composition proportion of the raw materials are controlled properly. Its morphology, microstructure, phase composition are characterized by scanning electron microscope（SEM） and X-ray diffraction（XRD） analysis. The MAF tests on plate of mold steel S136 are carried out without grinding lubricant to assess the finishing performance and service life of this new SiC magnetic abrasive. The surface roughness（Ra） of the plate worked is rapidly reduced to 0.051 μm from an initial value of 0.372 μm within 5 min. The MAF test is carried on to find that the service life of this new SiC magnetic abrasive reaches to 155 min. The results indicate that this process presented is feasible to prepare the new SiC magnetic abrasive; and compared with previous magnetic abrasives, the new SiC spherical composite magnetic abrasive has excellent finishing performance, high processing efficiency and longer service life. The presented method to fabricate magnetic abrasive through gas atomization and rapid solidification presented can significantly improve the finishing performance and service life of magnetic abrasive, and provide a more practical approach for large-scale industrial production of magnetic abrasive.
基金Project(51627805) supported by the National Natural Science Foundation of ChinaProject(2015A030312003) supported by the Natural Science Foundation of Guangdong Province,China+1 种基金Projects(2014B010129003,2015B020238008,2016B090931006,2017B090901025) supported by the Science and Technology Research Department of Guangdong Province,ChinaProject(201604016049) supported by the Science and Technology Bureau of Guangzhou City,China
文摘A self-developed double-nozzle gas atomization technique was used to produce AlSi10Mg powder.Effects of delivery tube diameter,gas pressure,and melt superheat on powder characteristics were investigated.The concepts of bluntness and outgrowth were introduced to analyze powder sphericity and satellite index quantitatively.The results showed that the median diameters of all atomized powders ranged from 25 to 33μm.The highest yield rate(72.13%)of fine powder(<50μm)was obtained at a superheat of 350 K.The powder size decreased with increasing melt superheat but increased with increasing delivery tube diameter.Powders with bluntness values between 96%and 98%accounted for over 60%.The outgrowth values demonstrated that 70%-85%of all powders did not contain satellite particles,with few powders adhered two or three particles.Not only Al and Si phases were present but also a metastable Al9Si phase was detected.
文摘Gas atomization was usually regarded as a good method for producing the spherical or approximate spherical powders. We found a lot of non-spherical powders in production processes, especially in larger particle size distribution area. The causes of producing non-spherical powders are explained and some analyses are done in order to find a better condition of producing spherical powders in this paper. The following morphologies were obtained by atomized Fe50 Co50 and pure iron and investigated by scanning electron microscopy （SEM）.
基金supported by the National Key Research and Development Program of China(No.2016YFB1100204)the Key Research&Development Plan of Jiangxi Province(No.20192ACB80001)the National Natural Science Foundation of China(Nos.52171163,51701214 and U1908219)。
文摘Gas atomization is now an important production technique for Fe-based amorphous alloy powders used in additive manufacturing,particularly selective laser melting,fabricating large-sized Fe-based bulk metallic glasses.Using the realizable k-εmodel and discrete phase model theory,the flow dynamics of the gas phase and gas-melt two-phase flow felds in the close-wake condition were investigated to establish the correlation between high gas pressure and powder particle characteristics.The locations of the recirculation zones and the shapes of Mach disks were analyzed in detail for the type of discrete-jet closed-coupled gas atomization nozzle.In the gas-phase flow feld,the vortexes,closed to the Mach disk,are found to be a new deceleration method.In the two-phase flow feld,the shape of Mach disk changes from“S”-shape to“Z”-shape under the impact of the droplet flow.As predicted by the wave model,with the elevation of gas pressure,the size of the particle is found to gradually decrease and its distribution becomes more concentrated.Simulation results were compliant with the Fe-based amorphous alloy powder preparation tests.This study deepens the understanding of the gas pressure impacting particle features via gas atomization,and contributes to technological applications.
基金the National Natural Science Foundation of China(Grant No.51975240)the Open Fund of State Key Laboratory of Advanced Forming Technology and Equipment(Grant No.SKL2019006).
文摘The paper aims at modeling and simulating the atomization process of the close-coupled ring-hole nozzle in vacuum induction gas atomization(VIGA)for metallic powder production.First of all,the primary atomization of the ring-hole nozzle is simulated by the volume of fluid(VOF)coupled large eddy simulation(LES)model.To simulate the secondary atomization process,we use the method of selecting the droplet sub-model and the VOF model.The results show that the ring-hole nozzle forms a gas recirculation zone at the bottom of the delivery tube,which is the main reason for the formation of an annular liquid film during the primary atomization.In addition,the primary atomization process of the ring-hole nozzle consists of three stages:the formation of the serrated liquid film tip,the appearance and shedding of the ligaments,and the fragmentation of ligaments.At the same time,the primary atomization mainly forms spherical droplets and long droplets,but only the long droplets can be reserved and proceed to the secondary atomization.Moreover,increasing the number of ring holes from 18 to 30,the mass median diameter(MMD,d_(50))of the primary atomized droplets decreases first and then increases,which is mainly due to the change of the thickness of the melt film.Moreover,the secondary atomization of the ring-hole nozzles is mainly in bag breakup mode and multimode breakup model,and bag breakup will result in the formation of hollow powder,which can be avoided by increasing the gas velocity.
基金the National Natural Science Foundation of China(No.52074157)Shenzhen Science and Technology Innovation Com-mission,China(Nos.JSGG20180508152608855,KQTD20170328154443162)Shenzhen Key Laboratory for Additive Manufacturing of High-performance Materials,China(No.ZDSYS201703031748354).
文摘Based on volume of fluid(VoF)interface capturing method and shear-stress transport(SST)k-ω turbulence model,numerical simulation was performed to reveal the flow mechanism of metal melts in melt delivery nozzle(MDN)during gas atomization(GA)process.The experimental validation indicated that the numerical models could give a reasonable prediction on the melt flow process in the MDN.With the decrease of the MDN inner-diameter,the melt flow resistance increased for both molten aluminum and iron,especially achieving an order of 10^(2) kPa in the case of the MDN inner-diameter≤1 mm.Based on the conventional GA process,the positive pressure was imposed on the viscous aluminum alloy melt to overcome its flow resistance in the MDN,thus producing powders under different MDN inner-diameters.When the MDN inner-diameter was reduced from 4 to 2 mm,the yield of fine powder(<150μm)soared from 54.7%to 94.2%.The surface quality of powders has also been improved when using a smaller inner-diameter MDN.
基金Project(51471035)supported by the National Natural Science Foundation of China
文摘The influence of cooling rate on the microstructure of Al0.6CoCrFeNi high entropy alloy（HEA） powders was investigated. The spherical HEA powders（D50≈78.65 μm） were prepared by high pressure gas atomization. The different cooling rates were achieved by adjusting the powder diameter. Based on the solidification model, the relationship between the cooling rate and the powder diameter was developed. The FCC phase gradually disappears as particle size decreases. Further analysis reveals that the phase structure gradually changes from FCC＋BCC dual-phase to a single BCC phase with the increase of the cooling rate. The microstructure evolves from planar crystal to equiaxed grain with the cooling rate increasing from 3.19×10^4 to 1.11×10^6 K/s.
基金Project(92066205)supported by the National Natural Science Foundation of ChinaProject(2019-Z10)supported by the State Key Lab for Advanced Metals and Materials of ChinaProject(FRF-MP-20-52)supported by the Fundamental Research Funds for the Central Universities,China。
文摘The almost completely dense copper was prepared by ultrafine copper powder prepared with both methods of electrolysis and novel water-gas atomization through cold isostatic pressing(CIP)and sintering under atmospheric hydrogen.Fine copper powder possesses the higher sintering driving force,thereby promoting shrinkage and densification during the sintering process.The grain size of sintered samples by electrolytic copper powder is smaller than that prepared by the atomized copper powder,and the twin crystals are particularly prone to forming in the former sintered microstructure due to the raw powder with low oxygen content and high residual stress originating from the CIP process.The relative density of samples by electrolytic and atomized powder at 1000℃ sintering temperature achieves 99.3%and 97.4%,respectively,significantly higher than that of the powder metallurgy copper parts reported in the literature.Correspondingly,the ultimate tensile strength and yield strength of samples by both kinds of copper powder are approximately similar,while the elongation of the sintered sample by the electrolytic powder(60%)is apparently higher than the atomized powder(44%).The superior performance of samples fabricated by electrolytic powder is inferred from the full density and low oxygen level for there is no cuprous oxide in the grain boundaries.
基金financially supported by the National High-Tech Research and Development Program of China (No. 2009AA033901)the National Natural Science Foundation of China (No. 51004019)
文摘17-4PH stainless steel powders were prepared using a supersonic nozzle in a close-coupled gas atomization system. The characteristics of powder particles were carried out by means of a laser particle size analyzer, scanning electron microscopy （SEM）, and the X-ray diffraction （XRD） technique. The results show that the mass median particle diameter is about 19.15 prn. Three main types of surface microstructures are observed in the powders： well-developed dendrite, cellular, and cellular dendrite structure. The XRD measurements show that, as the particle size decreases, the amount of fcc phase gradually decreases and that of bcc phase increases. The cooling rate is inversely related to the particle size, i.e., it decreases with an increase in particle size.
基金Project supported by the National Science Foundation of China (60777030, 50972061)the Natural Science Foundation for Distinguished Young Scientists of Zhejiang Province (R4100364)+1 种基金the Natural Science Foundation of Ningbo City (2009A610007,2010A610185)K.C. Wong Magna Fund in Ningbo University
文摘A novel technique for YAG:Ln(Ln=Eu,Ce) phosphor powder synthesis with a nanocrystalline structure was developed.Nanocrystalline YAG:Ln powder was prepared by an ultrasonic atomization and co-precipitation method using a mixture solution of ammonium hydroxide(NH3·H2O) and ammonium hydrogen carbonate(NH4HCO3) as precipitant.The as-prepared nano-powders were characterized by X-ray diffraction(XRD),scanning electron microscopy(SEM),and fluorescence spectrometer.The obtained phosphor powders were homogenous and in size of 50-70 nm.The results demonstrated that by using ultrasonic atomization and co-precipitation process,we could synthesize a good quality YAG:Ln(Ln=Eu,Ce) phosphor powder that had many potential applications.
基金the Major State Ba-sic Research Development Program of China (Nos. 2006CB605203 and 2006CB605204)
文摘Al-20Sn-1Cu powders were prepared by gas atomization in an argon atmosphere with atomizing pressures of 1.1 and 1.6 MPa. The characteristics of the powders are determined by means of dry sieving, scanning electron microscopy （SEM）, optical microscopy （OM）, and X-ray diffractometry （XRD）. The results show that the powders exhibit a bimodal size distribution and a higher gas pressure results in a broad size distribution. All particles in both cases are spherical or nearly spherical and satellites form on the surface of coarse particles. Dendritic and cellular structures coexist in the particle. With decreasing particle diameter, the secondary dendrite arm spacing （SDAS） decreases and the cooling rate increases. The particles processed under high gas atomization pressure （1.6 MPa） exhibit a lower SDAS value and a higher cooling rate than those of the same size under low gas atomization pressure （1.1 MPa）. The XRD results show that the Sn content increases with decreasing particle size.
文摘Super-clean and super-spherical FGH4095 superalloy powder is produced by the ceramic-free electrode inductionmelt inert gas atomization（EIGA） technique.A continuous and steady-state liquid metal flow is achieved at high-frequency（350 k Hz） alternating current and high electric power（100 k W）.The superalloy is immersed in a high-frequency induction coil,and the liquid metal falling into a supersonic nozzle is atomized by an Ar gas of high kinetic gas energy.Numerical calculations are performed to optimize the structure parameters for the nozzle tip.The undesired oxidation reaction of alloying elements starts at 1000℃ with the reaction originating from the active sites on the powder surfaces,leading to the formation of oxides,MexOy.The role of active sites and kinetic factors associated with the diffusion of oxygen present in the atomization gas streams are also examined.The observed results reveal that the oxidation process occurring at the surface of the produced powders gradually moves toward the core,and that there exists a clear interface between the product layer and the reactant.The present study lays a theoretical foundation for controlling the oxidation of nickel-based superalloy powders from the powder process step.
