Analysis of brush-molten metal interaction in brush atomizers: a CFD approach

Abstract

AbstractOptimizing the efficiency of metal powder production through brush atomization necessitates a comprehensive understanding of the interaction between the brush bristles and the molten metal, as well as its consequential effects on the fragmentation of the melt. Thus this study presents Computational Fluid Dynamics (CFD) models of the brush-melt interplay during the atomization of molten metals. The volume-of-fluid method was used to examine the various stages of melt fragmentation, from when the melt is discharged to when it settles on the brush bristles. The results revealed that the first breakup occurred close to the discharge orifice due to aerodynamic instability and fell within 13 < [Formula: see text]< 40.3. The nature of this breakup depends on the brush speed, bristle length, bristle diameter, brush density, and melt properties. A second breakup was observed when the melt contacted the rotating bristles. The melt bridges formed between two or more bristles due to attractive forces between the closely packed bristles induced by the capillary force of the melt and the surface tension of the meniscus surface are also overcome due to brush rotation. These results are in agreement with the experimental observations and are therefore sufficient for demonstrating the system.