New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

Priyadarshi, Abhinav; Bin Shahrani, Shazamin; Choma, Tomasz; Zrodowski, Lukasz; Qin, Ling; Leung, Chu Alex; Clark, Samuel J.; Fezzaa, Kamel; Mi, Jiawei; Lee, Peter D.; Eskin, Dmitry; Tzanakis, Iakovos

doi:10.1016/j.addma.2024.104033

Title: New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

Journal Article · 15 February 2024 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2024.104033 · OSTI ID:2305770

^[1]; Bin Shahrani, Shazamin ^[1]; Choma, Tomasz ^[2];

^[2];

^[3]; Leung, Chu Alex ^[4]; Clark, Samuel J. ^[5]; Fezzaa, Kamel ^[5]; Mi, Jiawei ^[6]; Lee, Peter D. ^[4];

^[7];

^[8]

Oxford Brookes University (United Kingdom)
Warsaw University of Technology (Poland); Amazemet Sp. z o.o., Ltd., Warsaw (Poland)
University of Wyoming, Laramie, WY (United States)
University College London (United Kingdom); Harwell Science and Innovation Campus, Didcot (United Kingdom)
Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)
University of Hull (Untied Kingdom)
Brunel University London (United Kingdom)
Oxford Brookes University (United Kingdom); University of Oxford (United Kingdom)

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.

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Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: Engineering and Physical Sciences Research Council (EPSRC); USDOE; USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2305770

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 83; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Additive manufacturing
Cavitation
Metal powder production
Ultrafast Synchrotron X-ray imaging
Ultrasonic atomization

Title: New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

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