Priyadarshi, A;
Bin Shahrani, S;
Choma, T;
Zrodowski, L;
Qin, L;
Leung, CLA;
Clark, SJ;
... Tzanakis, I; + view all
(2024)
New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing.
Additive Manufacturing
, 83
, Article 104033. 10.1016/j.addma.2024.104033.
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Abstract
Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fiber plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminum melt were used to study the atomization mechanism and the resulting droplet/powder characteristics, respectively. High-speed optical and ultrafast synchrotron X-ray imaging were used to study in situ the ultrasonic atomization dynamics, including pulsation and clustering of cavities inside the liquid layer/films, development of capillary waves, and formation of liquid droplets. For the first time, we observed and captured the occurrence of cavitation during the atomization of resting drops, films and impact droplets. The inertial cavitation events interfered with the capillary waves across the interphase boundary, puncturing and breaking the boundary to produce atomized mist. The in situ observation revealed the intricate dynamics of ultrasonic atomization and underscored the pivotal role of cavitation events throughout the entire atomization process. We also conducted experiments on ultrasonic atomization of liquid aluminum, producing particles of perfectly spherical shape. The particle size tended to decrease with reduced vibration amplitude Our work has demonstrated the important processing strategies on how to tailor the particle size while ensuring consistent particle shape and morphology, which is the key processing capability for producing high quality powders for additive manufacturing applications.
| Type: | Article |
|---|---|
| Title: | New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing |
| Open access status: | An open access version is available from UCL Discovery |
| DOI: | 10.1016/j.addma.2024.104033 |
| Publisher version: | http://dx.doi.org/10.1016/j.addma.2024.104033 |
| Language: | English |
| Additional information: | © 2024 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). |
| Keywords: | Ultrasonic atomization, Metal powder production, Additive manufacturing, Ultrafast Synchrotron X-ray imaging, Cavitation |
| UCL classification: | UCL UCL > Provost and Vice Provost Offices > UCL BEAMS UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Mechanical Engineering |
| URI: | https://discovery.ucl.ac.uk/id/eprint/10188601 |
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