Sliding Nozzle Assembly for Liquid Metal Atomizer
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Solution Overview
Problem
The nozzle used in the atomization process for producing metallic powders experiences wear and clogging, limiting the duration of the atomizing campaign and resulting in productivity and cost issues due to the need for frequent interruptions during continuous production.
Innovation Solution
A sliding nozzle assembly system that allows for quick replacement of nozzles during production, featuring a support structure enabling the nozzle assembly to move parallel to the liquid metal reservoir opening, minimizing disruption to the atomization process and incorporating refractory materials for durability and low friction coefficients to reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional fixed nozzle assembly is used in the atomizing process, then the nozzle remains stable during operation, but the production process must be interrupted frequently for nozzle replacement due to wear and clogging
Solution Approach 1:
The nozzle assembly is designed to be movable rather than fixed, allowing it to be slid along the support structure between different positions. This dynamic capability enables the nozzle to be quickly replaced during operation without interrupting the atomizing process, thereby resolving the contradiction between continuous production and maintenance requirements
Solution Approach 2:
Multiple nozzle assemblies are pre-positioned along the support structure at different locations. When a nozzle requires replacement, a ready-made nozzle is already in position or can be quickly moved into position, eliminating the need for lengthy replacement operations and maintaining continuous production capability
2Loss of time
If the nozzle assembly is made movable for quick replacement, then production downtime is reduced, but the complexity of the support structure increases
Solution Approach 1:
The support structure is segmented into multiple discrete positions or slots along the atomizing tower, with each position capable of holding a nozzle assembly. This segmentation allows for simple, modular positioning mechanisms rather than complex continuous movement systems, reducing overall structural complexity while enabling quick nozzle replacement
Solution Approach 2:
The support structure is designed with universal positioning capabilities that can accommodate multiple nozzle assemblies at different locations. The same support structure serves both as a structural framework and as a quick-change mechanism, eliminating the need for separate complex positioning systems
3Productivity
If refractory materials with low friction coefficients are used in the nozzle assembly, then wear is reduced and productivity increases, but the manufacturing cost increases
Solution Approach 1:
Refractory materials with low friction coefficients are applied only to specific high-wear areas of the nozzle assembly where contact with molten metal and atomizing fluid occurs, rather than the entire nozzle. This localized application reduces material costs while maintaining productivity benefits in the critical wear zones
Solution Approach 2:
The nozzle assembly uses composite material construction, combining refractory materials with low friction properties and other suitable materials in a layered or composite structure. This approach provides the necessary wear resistance and low friction characteristics while controlling overall manufacturing costs through optimized material selection and usage
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
Enables continuous production with reduced downtime and increased productivity by allowing rapid nozzle changes, maintaining stable product quality and minimizing wear on both the nozzle and support structure.
Implementation Method 1
The fluid hits the metal stream as it exits the nozzle, creating a turbulence which results in the formation of droplets
Implementation Method 2
incorporating refractory materials for durability and low friction coefficients to reduce wear
Data Source
AI summary
A method to quickly change a nozzle assembly suitable for use in a liquid metal atomizing process in which a liquid metal held in a liquid metal reservoir and exiting said metal reservoir through a reservoir opening is atomized by an atomizing fluid to form a metallic spray in an atomizing tower. A sliding nozzle assembly system in which replacement nozzles can be changed on the fly during production. A nozzle assembly designed to be used in conjunction with a support structure. Said nozzle assembly and support structure being designed for use in a nozzle change equipment according.