Lecture 4

Types of atomization

Dr. Nimu Chand Reger (Assistant Professor)

Metallurgical and Materials Engineering
National Institute of Technology Tiruchirappalli, Tamilnadu 620015
nimu@nitt.edu

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Types of Atomization
Atomization of molten metal can be done in different ways depending upon the
factors like economy and required powder characteristics. At present, water or
gas atomizing medium can be used to disintegrate a molten metal stream.
Following are types of atomization techniques
1. Water atomization
2. Gas atomization
3. Vacuum atomization
4. Centrifugal atomization
5. Rotating disk atomization
6. Ultra-rapid solidification processes
 1. Water atomization

High pressure water jets are used to bring

about the disintegration of molten metal
stream. Water jets are used mainly because of
their higher viscosity and quenching ability. This
is an inexpensive process and can be used for
small or large scale production. But water
should not chemically react with metals or
alloys used.
In water atomization, a high pressure water
stream is forced through nozzles to form a
disperse phase of droplets. Schematic view of
water atomization is shown in Fig. 4.1 Fig. 4.1 Schematic view of water atomization
• In this method, large quantities of energy are required to supply the water at
high pressure. It is estimated that the overall energy process efficiency is ≤ 4
%. This production method is significant for low and high alloy steels,
including stainless steel.

• Because of oxide formation, water atomization is not likely to be used in the

atomization of highly reactive metals such as titanium and the super alloys. In
general, water atomized powders are irregular in shape, with rough oxidized
surfaces.
Water atomizing process

Fig. 4.2 Flow chart for water atomization process

Ref : Powder Manufacturing & Characterization | EPMA Summer School, June 2016
 The advantages of high pressure water atomized powders are
summarized by Gummeson
1. Freedom to alloy
2. All particles have the same uniform composition
3. Control of particle shape, size and structure
4. Higher purity
5. Lower capital cost
Particle shapes of atomized powders can be modified from almost perfectly spherical to highly irregular, by
controlling the processes which take place in the interval between disintegration of the liquid metal stream and the
solidification of the drop. Figure 4.3 illustrates some major variables in the atomizing process.

Fig. 4.3 Major variables in the atomizing process.

Sphericity of a metal powder is favoured by:

(a)High metal surface tension

(b) Narrow melting range
(c) High pouring temperature
(d) Gas atomization, especially inert gas
(e) Low jet velocity
(f) Long apex angles in water atomization
(g) Long flight paths.

In water atomization, water pressures are commonly in the range of 35 × 105 Pa to 210 × 105
Pa with associated water velocities from 40 m.s–1 to 15 m. s–1 .
The particle cooling rate is ~ 103 K.s–1 to 104 K.s–1.
Fine particle sizes are favoured by
(a)Low metal viscosity
(b) Low metal surface tension
(c) Superheated metal
(d) Small nozzle diameter, i.e. low metal feed rate.
(e) High atomizing pressure
(f) High atomizing agent volume
(g) High atomizing agent velocity
(h) High atomizing agent viscosity
(i) Short metal stream
(j) Short jet length
(k) Optimum apex angle (ao ).
The surface tension of liquid metals is high and a droplet once formed tends to
assume the spherical shape.
The higher the viscosity of the atomizing medium, the greater is the
deformation of the droplet.
The higher the cooling rate, the shorter is the time during which the surface
tensional forces can operate to spheroidize the droplet and, therefore, the
more irregular the particle shape. Impurities and alloying elements in the
metal or reactions on the surface of the droplets that decrease the surface
energy, will promote irregular particle shapes.
Small quantities of phosphorus in copper lead to formation of a P2O5 film at the
particle surfaces which increase the surface energy and results in the
formation of spherical droplets.
The existence of a solid oxide film such as ZnO acts in the opposite fashion,
tending to give less rounded particles. The addition of silicon is a well-known
method of influencing the particle shape of atomized stainless steel powder.
While the particle shape is not appreciably influenced by metal pouring temperatures in gas
atomization, it is in water atomized powders.

At higher pouring temperatures, there remains enough superheat after atomization to allow
surface tension forces to create spheroids. Higher water pressure results in more irregular
particle shapes due to greater impact forces and to larger volumes of water with resultant
more rapid quench.

Another aim during atomization of particularly multiphase alloy systems is the elimination of
gross metal segregations. The particle structure is therefore, a function of the solidification
rate.

A fine microstructure particle is promoted with water atomization as opposed to gas

atomization, by lower metal pouring temperatures, higher atomizing agent pressure, flow
rate and viscosity and by shorter particle flight paths.
Water atomized powder
A SEM fine microstructure of different powder particles is shown below

Fig. 4.4 Typical SEM micrograph of different metal powder particles

2. Gas atomization

• Used for the production of more

oxidation sensitive materials that would
be very difficult to produce via water
atomization
• Schematic unit of gas atomization unit
shown in Fig 4.5.
• Production of high purity powders for
special applications
• Spherical powders

Fig 4.5 Schematic view of gas atomization unit

Gas atomization conti…
The general atomizing media are nitrogen, argon or air. Various atomization
geometries are used in commercial practice.
In what is known as ‘external mixing’ (Fig. 4.6), contact between the atomizing
medium and melt takes place outside the respective nozzles. This type of
mixing is used exclusively for the atomization of metals. ‘Internal mixing’ (Fig.
4.6) is quite common for the atomization of materials which are liquid at room
temperature.
The axes of the gas jets are equally inclined to the melt stream axis and
intersect this axis at the geometrical impingement point. The process is
governed by a number of interrelated operating parameters.
Controllable variables include jet distance, jet pressure, nozzle geometry,
velocity of gas and metal, and melt superheat.
Fig. 4.6 Two fluid atomization design
Gas atomized powders are typically spherical, with relatively smooth surfaces.
Higher pressure and/or a smaller jet distance produce finer powder. Gas
atomization pressures are typically in the range 14×105 Pa to 42×105 Pa at gas
velocities from 50 m.s–1 to 150 m.s–1; under these conditions, the particle
quench rate is ~102 K.s–1.
Such production method is used for preparing powders of the superalloys,
titanium, high speed steel and other reactive metals.
The method suffers from a very low overall energy efficiency (~3 %) and is
expensive if inert gases other than nitrogen have to be used.
 3. Vacuum atomization

Vacuum or soluble gas atomization is a commercial batch process based on the

principle that when a molten metal supersaturated with gas under pressure is
suddenly exposed to vacuum, the gas expands, comes out of solution, and
causes the liquid metal to be atomized.
Alloy powders based on nickel, copper, cobalt, iron and aluminium can be
vacuum atomized with hydrogen. Powders are spherical, clean and of a high
purity compared to powders produced by other processing methods.
The process was developed and patented by Homogeneous Metal, Inc. Figure
4.7 illustrates a schematic of the equipment used for the atomization process.
The principal use of powder made by vacuum atomization has been for the
production of gas turbine disks and intricate parts by injection moulding
Fig. 4.7 a Schematic representation of
Fig. 4.7 b Labelled Schematic representation of
vacuum atomization. (a) trap door, (b)
vacuum atomization
transfer tube, (c) molten metal.
 4. Centrifugal atomization
The primary commercial adaptation of centrifugal atomization is the rotating electrode process (Fig. 4.8.
The metal or alloy to be atomized, in the form of a consumable cylindrical electrode (65mm diameter x
1524mm), is rotated at speeds of about 15 000 rpm while the end of the electrode (anode) is melted by an
arc. The molten metal is ejected by centrifugal force in the form of droplets from the periphery of the bar.

A transferred arc helium plasma torch (plasma rotating electrode process) is used in order to avoid
contamination by tungsten, characteristic of earlier designs. Helium gas in the working chamber enhances
arc stability and convective cooling efficiency. Powders atomized by this technique are of high purity since
there is no containment of the molten metal.

The powders are spherical and satellite free (Fig. 4.8) and in the size range 50µm to 400µm with a median
particle size of about 200µm. Droplet cooling rates (˂1-102°C s−1) are lower than in water or gas
atomization.
Fig. 4.8 Commercial modes of centrifugal atomization
Fig. 4.9 Scanning electron micrographs of atomized powders. (a) water atomized iron powder; (b) gas atomized
high carbon steel; (c) centrifugally atomized nickel-base superalloy (plasma rotating electrode process); (d)
vacuum atomized nickel-base
A. Commercial water atomized powders are normally irregular in shape with a median
particle size of about 100 µm (Fig. 4.9(a)). Particle size of distributions are relatively broad
(10–300 µm). Cooling rate is a function of particle size and is estimated to be ˃1 x 103°C s-1 .

B. Commercial gas atomized powders are normally spherical in shape with small satellites
attached (Fig. 4.9 (b)). Median particle size is in the range of 50µm to 300µm. For a given
particle size, cooling rate is about one order of magnitude lower than in water
atomization.

C. The powders are spherical and satellite free (Fig. 4.9(c)) and in the size range 50µm to
400µm with a median particle size of about 200µm.

D. Vacuum atomized powders are smooth and spherical with very few satellite particles in
evidence. Powder size range is broad (1–500µm) with a median particle size of 40–70µm.
A representative micrograph of a vacuum atomized nickel-base superalloy powder is
shown in Fig. 4.9 (d).
5. Spinning/Rotating disk atomization
Objective : Design a compact equipment setup for the continuous production of Alginate
hydrogel microspheres by spinning disk atomization (SDA) technique ensuring high
production rate.

About SDA
1. SDA is a technique to achieve liquid atomization
2. The Liquid is introduced to the surface of a high speed rotating disk
3. Liquid gains velocity and leaves the edge of the disk in the form of fine droplets
4. SDA can be used for micro encapsulation in which particles having a core material
engulfed in a matrix is made
5. Micro encapsulation finds applications in food, cosmetics, pharmaceuticals and
detergents
Principles of design
Sodium Alginate (a bio-polymer) and copper sulphate are used as the reactants to
form encapsulated hydrogel beads

Sodium Alginate solution is made to form micro-droplets by SDA

The micro-droplets react with copper sulphate solution to form copper Alginate
microencapsulated hydrogel beads

Separation of product hydrogel beads from the reaction slurry and recycle of
unreacted copper sulphate solution for reaction

The design aims for continuous operations at high production rate in a compact setup
 System outline
The setup consists of three main units
(1) Reaction unit : consists of
(a) spinning disk assembly
(b) Copper sulphate film forming zone
(c) Reaction and slurry collection zone
(2) Separation Unit : Consists of
(a) product filtration assembly
(b) product storage system
(3) Reactant recycle and storage units, Consists of
(a) copper sulphate storage and recycle system
(b) Sodium Alginate storage and supply system
Reaction unit design features
Film forming zone, reaction and slurry collection zone are contained in a
single vessel.

A thin film of copper sulphate is formed at the inner surface of the conical
vessel using an annular concentric arrangement

The spinning disk-motor assembly is positioned concentric to the reaction

vessel

The micro droplets from the disk contacts the solution at the inner wall of
the vessel to form hydrogel beads
Reaction unit design features
In many applications, it becomes necessary to “atomize” a body of liquid,
disintegrate it into tiny and preferably uniform droplets, by manipulating the
action of capillary forces that create them. One of the most efficient and cheap
ways of doing this is via the process known as spinning disk atomization (SDA).

The essence of the process is that a continuous stream of fluid is fed onto the
central area of a horizontally orientated disk spinning about its vertical axis so
that the centrifugal force drives the fluid away from the axis of rotation
ensuring a continuous film flow over the disk’s surface, and as the fluid reaches
the disk’s rim, it leaves the disk and breaks into drops.
Present and Future activities
1. The primary model for the reaction unit is made and trials are being
carried out
2. The optimum design for the reaction unit will be established
through these trials
3. The selection and sizing of the down stream units will be done
based on the final design parameters of the reaction unit
4. Fabrication of the whole unit and stabilization of the operation will
be done
5. Advanced encapsulation requirements such as production of
multiple core microspheres can be tried in future through suitable
modifications once the stable operation is established
6. Ultra rapid solidification
A solidification rate of 1000 C/s is achieved in this process. This results in
enhanced chemical homogeneity, formation of metastable crystalline
phase, amorphous material.

If the cooling rate of an atomized liquid is increased, ultra-fine or

microcrystalline sized grains can form Some metals can solidify without
becoming crystalline (called amorphous materials)

Amorphous materials can have high strength, improved corrosion

resistance, and reduced energy to induce and reverse magnetization
When the cooling rate of the atomized liquid is increased, ultra-fine
particles can form with littlie or no crystallinity (amorphous powders).

Amorphous materials can have proper4es different from their crystalline

counterparts, such as increased strength, improved magnetization
behaviour, improved corrosion resistance, etc.

Example: Amorphous metal transformer cores lose about 60 to 70% less

energy in magnetization than conventional silicon steels.
 For listening

Any questions
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