Concentric Ring Gas Atomizer Nozzle for ODS Steel
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Solution Overview
Problem
Existing high-pressure gas atomization nozzles struggle to produce ultra-fine oxide dispersion strengthened (ODS) ferritic stainless steel powders with a narrow particle size distribution, which is crucial for advanced power systems and additive manufacturing, due to limitations in controlling the atomizing gas structure and the resulting particle size distribution.
Innovation Solution
A gas atomizing nozzle with concentric ring arrays of discrete gas jet orifices and independent gas supply manifolds is used to control the atomizing gas structure, allowing for different pressures and compositions to enhance the production of fine atomized powders with a narrower particle size distribution, specifically targeting the production of ODS stainless steel powders with ideal size yields for additive manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single ring of discrete gas jets is used, then the device complexity is reduced, but the manufacturing precision of particle size distribution deteriorates
Solution Approach 1:
The gas jet system is segmented into multiple concentric rings with discrete jets in each ring, allowing independent control of gas flow patterns to achieve precise control over atomization process and particle size distribution
Solution Approach 2:
The gas jet arrangement transitions from a single-plane configuration to a multi-dimensional concentric ring structure, adding radial and axial dimensions of control to achieve superior particle size uniformity
2Productivity
If higher gas pressure is applied to increase atomization intensity, then the productivity of fine powder production is improved, but the manufacturing precision of particle size distribution deteriorates
Solution Approach 1:
The system independently controls gas pressure parameters for each concentric ring of jets, enabling optimization of pressure distribution to maintain both high productivity and narrow particle size distribution
Solution Approach 2:
Different regions of the atomization zone are provided with different gas pressure levels through the multi-ring structure, creating localized optimization zones that simultaneously achieve high production rate and uniform particle size
3Manufacturing precision
If the gas jet orifice size is reduced to increase atomization fineness, then the manufacturing precision of particle size is improved, but the device complexity increases
Solution Approach 1:
The atomization function is segmented across multiple concentric rings with multiple discrete jets per ring, allowing the use of smaller individual orifices while distributing the complexity across a systematic modular structure
Solution Approach 2:
Multiple rings of gas jets are nested concentrically around the melt delivery tube, creating a compact multi-layer structure that achieves fine atomization without proportionally increasing overall device complexity
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
The nozzle design achieves a more uniform and controlled production of fine atomized powders with a narrower particle size distribution, particularly in the range of 20 to 75 μm, improving the yield of ultra-fine powders and maintaining a consistent Y to O ratio, essential for advanced materials and additive manufacturing applications.
Implementation Method 1
close-coupled gas atomization: high frame rate analysis of spray-cone geometry
Implementation Method 2
The formation of the Mach disk truncates the recirculation zone and isolates the wake region, resulting in deep aspiration at the exit orifice of the melt delivery tube
Implementation Method 3
supersonic atomization gas along the periphery of the tube
Implementation Method 4
forced the liquid to bloom and spread or film across the transverse landing of the melt delivery tube prior to being sheared by supersonic atomization gas along the periphery of the tube
Implementation Method 5
Liquid fragments or droplets are abruptly decelerated as they pass through the Mach disk and crash into the high pressure stagnation front, which helps to further disintegrate the liquid into a fine mist
Implementation Method 6
Liquid fragments or droplets are abruptly decelerated as they pass through the Mach disk and crash into the high pressure stagnation front
Implementation Method 7
nascent atomized droplets react with small amounts of O2 within the reactive atomization gas to form an ultra-thin (t2O3)
Implementation Method 8
Heat treatment of the consolidated powders results in an oxygen exchange reaction between the Cr-enriched prior particle boundary (PPB) oxide and Y-enriched IMC precipitates
Implementation Method 9
Heat treatment of the consolidated powders results in an oxygen exchange reaction between the Cr-enriched prior particle boundary (PPB) oxide and Y-enriched IMC precipitates
Data Source
AI summary
A concentric ring gas atomization nozzle with isolated gas supply manifolds is provided for manipulating the close-coupled atomization gas structure to improve the yield of atomized powders.