Atomization simulation and preparation of GH3536 powders at different atomization pressures
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摘要: 使用真空感应熔炼气体雾化方法，在不同雾化压力（7、8、9 MPa）下制备了球形GH3536合金粉末。通过使用多相流模型和离散相模型对喷嘴下方区域进行了数值模拟，再现了不同雾化气压下的一次雾化和二次雾化过程。实验和模拟的结果表明：回流区的气体速度和滞止压力随雾化气压的提高而增加，雾化气压的增加使粉末粒度不断减小，模拟结果与实验结果吻合，验证了雾化模型的可靠性。提高雾化气压可提高细粉收得率，但颗粒尺寸的减小和颗粒形貌的改变会对粉末的流动性能造成直接影响，在雾化压力8 MPa下制备的粉末具有最佳的流动性和松装密度，分别为14.34 (s·50g−1)和4.728 g·cm−3。Abstract: Spherical GH3536 alloy powders were prepared by vacuum induction-melting gas atomization method at the different atomization pressures (7, 8, 9 MPa). The region below the nozzle was numerically simulated by multiphase flow model and discrete phase model, and the primary and secondary atomization processes at the different atomization pressures were reproduced. In the results, the flow velocity and stagnation pressure in the recirculation zone increase with the increase of atomization pressure. With the increase of atomization pressure, the powder particle size decreases continuously. The simulation results are similar with the experimental results, verifying the reliability of the atomization model. The increase of atomization pressure can increase the yield of fine powders, but the decrease of particle size and the change of particle morphology may directly affect the powder flowability. The powders prepared at the atomization pressure of 8 MPa show the best flowability and the optimum apparent density, which are 14.34 (s·50g−1) and 4.728 g·cm−3, respectively.
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图 3 单相气体流场速度分布（a）和流场内速度方向（b）
Figure 3. Velocity distribution of the single-phase gas vector field (a) and the velocity direction in the vector field (b)
图 5 不同雾化压力下雾化流场中心线上压力变化曲线
Figure 5. Static pressure curves at the different atomization pressures
图 7 一次雾化过程中不同雾化气压下熔滴尺寸：（a）7 MPa；（b）8 MPa；（c）9 MPa
Figure 7. Droplet size at the different atomization pressures during the primary atomization simulation: (a) 7 MPa; (b) 8 MPa; (c) 9 MPa
图 9 二次雾化后的颗粒尺寸分布：（a）7 MPa；（b）8 MPa；（c）9 MPa；（d）累积分布曲线
Figure 9. Particle size distribution obtained by the secondary atomization simulation: (a) 7 MPa; (b) 8 MPa; (c) 9 MPa; (d) cumulative distribution curves
图 10 不同雾化气压下真空感应熔炼气体雾化法制备GH3536颗粒扫描电子显微形貌：（a）7 MPa；（b）8 MPa；（c）9 MPa
Figure 10. SEM images of the GH3536 alloy powders prepared by VIGA at the different atomization pressures: (a) 7 MPa; (b) 8 MPa; (c) 9 MPa
图 11 不同雾化气压下粉末粒径分布：（a）7 MPa；（b）8 MPa；（c）9 MPa；（d）累积分布曲线
Figure 11. Particle size distribution at the different atomization pressures: (a) 7 MPa; (b) 8 MPa; (c) 9 MPa; (d) cumulative distribution curves
图 12 不同雾化气压下GH3536粉末流动性和松装密度
Figure 12. Flowability and apparent density of the GH3536 powders at the different atomization pressures
表 1 真空感应熔炼气体雾化过程模拟中氩气和GH3536合金物理性质[21]
Table 1. Physical properties of the argon and GH3536 superalloys in VIGA process simulation[21]
材料 密度 / (kg·m−3) 比热容 / (J·kg−1·K−1) 热导率 / (W·m−1·K−1) 黏度 / (kg·m−1·s−1) 温度 / K 氩气 1.66 520.64 0.02 2.13×10−5 300 GH3536 7280.00 677.00 29.00 5.50×10−3 1780 
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表 2 不同雾化气压下真空感应熔炼气体雾化制备粉末和数值模拟粉末中位粒径
Table 2. Experimental and simulation data of the median particle size for the GH3536 superalloy powders by VIGA
雾化气压 / MPa 模拟中值粒径 / μm 实验中值粒径 / μm 7 42.53 41.48 8 38.36 36.88 9 34.88 32.63
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