Multi-Jet Gas Atomization for Fine Powder Production
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Solution Overview
Problem
Current gas atomization methods face inefficiencies in producing fine spherical particles with a narrow particle size distribution, particularly below 100 microns, and require high gas pressures and expensive gases, leading to increased production costs and poor particle morphology.
Innovation Solution
The use of a gas flow production system with parallel, isobaric gas flows emitted at an angle of 90±45 degrees to a melt flow, increasing collision surfaces and energy transfer, allowing for efficient production of fine particles with a narrow size distribution using lower pressures and inexpensive gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gas atomization methods are used, then particles can be produced, but the particle size distribution is wide and spherical morphology is poor
Solution Approach 1:
The single gas flow is segmented into multiple parallel gas flows (e.g., 3-10 jets) arranged in a array. Each jet independently atomizes the melt stream, creating multiple collision surfaces that produce more uniform and spherical particles with narrower size distribution.
Solution Approach 2:
The atomization process transitions from a single-direction gas flow to a multi-dimensional array of parallel gas flows. The jets are arranged perpendicular to the melt stream, creating a two-dimensional array of collision points that improves particle morphology and size uniformity.
2Manufacturing precision
If high gas pressure is used to produce fine particles, then particle size can be reduced, but production cost increases due to expensive gases and high pressure requirements
Solution Approach 1:
The system uses multiple parallel gas jets operating at moderate pressures (e.g., 2-10 bar) instead of a single high-pressure jet. The cumulative effect of multiple jets at lower pressures achieves fine particle production (below 100 microns) with reduced cost and improved safety.
Solution Approach 2:
The atomization function is divided among multiple gas jets, each contributing to the overall particle size reduction. This segmentation allows the use of lower pressure per jet while achieving the same or better fine particle production compared to a single high-pressure jet.
3Device complexity
If single gas flow is used for atomization, then device complexity is low, but collision surface area is limited and atomization efficiency is poor
Solution Approach 1:
The single gas flow is divided into multiple parallel jets arranged in an array. This segmentation increases the total collision surface area between gas and melt, dramatically improving atomization efficiency and fine particle production without requiring complex equipment.
Solution Approach 2:
Multiple parallel gas jets are combined in a coordinated array, all acting simultaneously on the melt stream. The merged effect of multiple jets creates extensive collision surfaces that enhance atomization efficiency while maintaining relatively simple device architecture.
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 approach achieves high efficiency in producing particles with diameters less than 100 microns (99%), 50 microns (90%), and 20 microns (60%), with improved spherical morphology and reduced satellite particles, while reducing operating costs by using lower pressures and inexpensive gases.
Implementation Method 1
collision of at least some of the plurality of gas flows with the melt flow in the atomizing chamber disintegrate the melt flow to produce the powder
Implementation Method 2
the droplets may be solidified to produce a powder
Data Source
AI summary
In accordance with some embodiments herein, a method for producing a powder from a material is provided. The material may be melted in a melt furnace to produce a melted material. The melted material may be conducted through a melt nozzle to emit, from the melt nozzle, a melt flow traveling through an atomizing chamber. A plurality of gas flows may be emitted through a plurality of orifices of a gas flow production device towards the melt flow. Collision of at least some of the plurality of gas flows with the melt flow in the atomizing chamber disintegrate the melt flow to produce the powder.