Study of liquid spreading and particle size distribution during the preparation of aluminum alloy powder by rotary disc atomization
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摘要: 为研究高球形度、高粒径集中度、无卫星粉的增材制造用铝合金粉末制备技术，开发了一套高温转盘雾化实验装置。基于该装置，研究了铝液的流动铺展规律，发现、命名并分析了转盘表面存在的4个典型区域。采用扫描电子显微镜（SEM）分析了1060纯铝和AlSi10Mg铝合金粉末样品的微观结构。采用单峰Extreme模型，对典型实验的粉末粒径分布曲线进行了拟合分析。研究结果表明：铝液流量减小引起了分裂模式转变，进而提高了细粉率、降低了中位径。研究对比了平面、锥面和弧面等3种盘面构型对中位径的影响。分析了转盘直径和转速对1060纯铝粉中位径的影响规律，通过线性回归拟合得到了一个新的中位径理论公式。Abstract: An experimental setup using high temperature rotating disc centrifugal atomization was developed to study the preparation technology of the aluminum alloy powder for additive manufacturing with high sphericity, high particle size concentration and no satellite powder. The flow spreading pattern of the aluminum liquid was investigated, and four typical regions were found to exist on the surface of the disc, which were named and analyzed. The microstructures of the 1060 and AlSi10Mg powder samples were analyzed by scanning electron microscopy (SEM). The powder particle size distribution curves for typical experiments were analyzed by fitting a single-peak Extreme model. A shift in the splitting mode caused by a decrease in the flow rate of the aluminum liquid was investigated, which was effective in increasing the fines rate and reducing the median diameter. The effects of three different disk configurations, plane, tapered and curved, on the median diameter were compared. The effect law of the rotational speed and disc diameter on the median diameter of 1060 aluminum powder was analyzed, and a new theoretical formula of the particle size was obtained by regression analysis.
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Key words:
- multiphase flow /
- powders /
- preparation /
- size distribution /
- rotary disc /
- atomization /
- aluminum alloy
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图 1 高温转盘雾化制粉实验装置示意图
Figure 1. Schematic diagram of high-temperature rotary disc atomi-zation powder-making experimental device
图 2 高温转盘雾化制粉实验装置照片
Figure 2. Photograph of high temperature disc atomization powder making experimental device
图 4 转盘雾化制备球形铝粉的实验图片
Figure 4. Picture of spherical aluminum powder prepared by centrifugal atomization of rotating disc
图 6 转盘表面各典型区域命名
Figure 6. Description of the different typical areas on the disc surface
图 7 转盘边缘锯齿形雾化点照片
Figure 7. Photo of the jagged atomization point on the edge of the disc
图 8 粒径15～53 μm的粉末扫描电镜图片
Figure 8. Scanning electron microscope images of powders between 15-53 μm
图 10 粉末粒径差分分布、累积分布及Extreme函数拟合
Figure 10. Particle size differential distribution, cumulative distribution, and Extreme fit
图 12 不同流量下的粉末粒径分布和累积分布
Figure 12. Powder particle size distribution and cumulative percentage at different flow rates
图 13 不同转速下的粉末中位径实验值与计算值对比
Figure 13. Comparison of experimental data and theoretical values of d50 at different rotational speeds
图 14 不同转盘直径下的粉末中位径实验值与计算值对比
Figure 14. Experimental data and theoretical values of median diameter of powders with varying disc diameters
图 15 不同转盘构型下的粉末粒径统计
Figure 15. Particle size statistics for different disc configurations
图 16 1060纯铝粉中位径实验值及线性拟合曲线
Figure 16. Data of median diameter of 1060 pure aluminum with atomization parameters and linear fitting curve
表 1 1060纯铝的化学成分（%）
Table 1. Chemical composition of 1060 pure aluminum (%)
Al Fe Si Cu Zn V Mn Mg Ti 99.6 0.35 0.25 0.05 0.05 0.05 0.03 0.03 0.03 
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表 2 AlSi10Mg铝合金的化学成分（%）
Table 2. Physical properties of 1060 pure aluminum (%)
Al Si Zn Mg Fe Mn Ti Cu Ni Sn Pb else 9.70 0.60 0.50 0.50 0.40 0.10 0.07 0.05 0.05 0.05 注：“else”表示铝合金中除其他化学成分外，其余皆为Al的含量。
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表 3 1060纯铝的物理性质
Table 3. Physical properties of 1060 pure aluminum
Temperature
/KDensity
/（g·cm−3）Viscosity
/（Pa·s）Surface tension
coefficient /（N·m−1）1150 2.310 0.926 × 10−3 0.843
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Temperature
/KDensity
/（g·cm−3）Viscosity
/（Pa·s）Surface tension
coefficient/（N·m−1）1150 2719 1.3 × 10−3 0.826
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表 5 离心分裂模式转变临界流量
Table 5. Centrifugal atomization critical flow rate at different speeds
ω/（r·min−1） D/mm Q1 /（mL·s−1） Q2 /（mL·s−1） 6000 59 2.47 46.93 12000 59 1.63 30.97 18000 59 1.28 24.28 24000 59 1.08 20.43
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