Atomizer Nozzle Tapered Cover for Uniform Metal Powder
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Solution Overview
Problem
Existing atomizer nozzles face issues with non-uniform metal powder particle size due to diffusion of swirling gas flow before reaching the molten metal, leading to insufficient shearing force and instability in metal powder production.
Innovation Solution
An atomizer nozzle design featuring a molten metal nozzle with a gas nozzle that introduces gas tangentially and forms a swirling flow, which is guided by a tapered cover extending below the nozzle to maintain high angular velocity and apply a consistent shearing force, along with a diameter expansion surface to enhance gas speed and prevent nozzle blocking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the nozzle hole is disposed above the discharge port of the molten metal nozzle, then the gas can be introduced into the chamber, but the swirling flow component diffuses and is lost before reaching the discharge port, resulting in insufficient shearing force
Solution Approach 1:
The invention extends the cover in the vertical dimension below the discharge port, transforming the gas introduction geometry from a single-plane configuration to a multi-level spatial arrangement. This dimensional extension allows the swirling flow to maintain its intensity over a longer path and apply shearing force more effectively at the discharge port location.
Solution Approach 2:
The cover is designed to extend below the discharge port to preliminarily guide and maintain the swirling flow before it reaches the discharge port. This preliminary positioning ensures that the gas flow arrives at the discharge port with sufficient angular velocity and coherent swirling structure, preventing diffusion and loss of the shearing force component.
2Force
If the flow speed of the gas is increased to increase the shearing force, then the shearing force increases, but the gas flows interfere with each other in the circumferential direction, resulting in unstable metal powder production
Solution Approach 1:
The invention divides the gas introduction into multiple segments through the tapered cover structure, which guides different portions of the gas flow along the tapered surface. This segmentation prevents circumferential interference between gas flows while maintaining high individual flow speeds, as each gas stream follows a defined path along the taper without conflicting with adjacent streams.
Solution Approach 2:
The tapered cover provides locally optimized flow guidance at different angular positions around the discharge port. Each local region of the tapered surface guides the gas flow with appropriate angular velocity and direction, ensuring that shearing force is uniformly distributed in the circumferential direction without flow interference, thereby stabilizing metal powder production.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures a stable and uniform shearing force is applied to the molten metal, resulting in a more uniform metal powder particle size and improved recovery rate by maintaining the swirling flow's intensity and direction.
Implementation Method 1
a gas nozzle including a chamber having an inner peripheral surface surrounding an outer periphery of the molten metal nozzle, an introduction portion which is configured to introduce a gas to the chamber toward a circumferential direction of the molten metal nozzle
Implementation Method 2
A shear force acts by the jet of a gas and the molten base metal is split and atomized
Implementation Method 3
the cover is provided with a tapered inner peripheral surface which is connected to the inner peripheral surface of the chamber and has a diameter which decreases toward a lower end portion of the inner peripheral surface
Implementation Method 4
the molten base metal is split and atomized
Implementation Method 5
A shear force acts by the jet of a gas and the molten base metal is split and atomized
Data Source
AI summary
An atomizer nozzle includes: a molten metal nozzle extending in a vertical direction and which allows a molten metal to flow downward from a lower end thereof; and a gas nozzle including a chamber having an inner peripheral surface surrounding an outer periphery of the molten metal nozzle, a blow portion which introduces a gas to the chamber toward a circumferential direction of the molten metal nozzle, and a cover extending from the chamber to a position below the lower end of the molten metal nozzle while surrounding the molten metal nozzle, wherein the cover is provided with a tapered inner peripheral surface connected to the inner peripheral surface of the chamber and of which diameter is decreased as close to a lower end portion of the tapered inner peripheral surface.