Abstract
The literature on atomization of melts has been reviewed. Models have been developed and applied to analyze the phenomena associated with centrifugal atomization of melts using rotating disk method. Some suggestions and guidelines for the development and operation of a centrifugal atomizer have been given. Previous experiments of melt atomization and present observations of water disintegration at the edge of a rotating disk have confirmed that the disintegration of melts or water occurs in one of three basic modes: direct droplet formation (DDF), ligament formation (LF) and film formation (FF). Wave theories have been used to analyze the disintegration of melts in the different regimes. The equations for the fastest growing wave number have been derived. Models for the calculation of powder particle sizes have been suggested and the calculated results have compared with available experimental data in the literature. Calculations have shown that disk diameter and disk rotating speed are two very important atomizing parameters. The type of melt and melt superheat also affect the powder particles size. In general, fine powder particles can be obtained by increasing disk rotating speed and using large diameter disk, provided that the melt does not solidify on the disk. In the DDF regime waves forming at the periphery of a disk are responsible for the break up of melts. The fastest growing wave number depends on the disk speed, disk diameter and properties of melt. In the FF regime sheet wave theory of Dombrowski and Johns was used to study the collapse of the melt sheet. The fastest growing wave number is a complex function of the speed and thickness of film and the properties of melt and atomizer atmosphere. The effects of disk diameter, disk rotating speed and melt flow rate on atomization are achieved through influencing the speed and thickness of film. The studies on the flow of melts on rotating disks have shown that the film forming on the disk was very thin, about tens of microns and the tangential velocity of melts was much higher than the radial velocity. The analysis of heat transfer of melts on a rotating disk has shown that partial solidification of melts on the disk is possible. To obtain a good atomization condition it is necessary to control the partial freezing of melts on the disk. A large melt superheat and a high melt flow rate are required to prevent melts from freezing on the disk. The use of a small diameter disk can also avoid freezing of the melt on the disk. Combining the calculations of heat transfer on the disk with the prediction of wave theory for particle sizes, it is shown that a disk of small diameter rotating at high speed is desirable for the production of fine powders.The cooling ability obtained by centrifugal atomization using the rotating disk method depends on the design of atomizer, the operating conditions and the type of material to be atomized. A large diameter disk on which solidification of melt is avoided and a high disk rotating speed result to the formation of fine powder particles which experience a high cooling rate. The nucleation undercooling of melt depends on particle size, disk speed, material to be atomized and the nucleation condition. A small particle size and a high disk speed lead to a large undercooling. The times for the completion of solidification of powder particle of typical sizes produced by centrifugal atomization have been calculated and their effects on the atomizer vessel diameter have been discussed.