Optimize atomizer set up

Atomization is generally carried out using an inert carrier gas which forces the molten powder through a nozzle and then cools the droplets into highly spherical powders. The physics of gas atomization of metal powder involves multiphase gas flow, heat transfer, droplet formation, and solidification. The interaction between these individual mechanisms complicates understanding and modeling of the process. In addition, the chemical activity between some metals introduces further complexity.

To increase the powder yield, improve the powder quality, and reduce the production cost, a thorough understanding of the process and a comprehensive experimental investigation are needed to guide the design of the gas atomizer and to determine optimal settings of critical process variables.

In atomization, an on-line particle size analyzer that gives immediate size data can be used to optimize the process in real-time. This will reduce set-up times and batch-to-batch variation and result in a more consistent product.