Numerical analysis of a specific hybrid atomization gun

In this study, a unique gun was designed to be used in a new atomisation technique called Hybrid atomisation by combination of plasma atomisation (PA) and gas atomisation (GA) methods for the production of powders of metals and alloys with high melting temperatures. The interaction of the two different atomisation methods was investigated in the 3D modelled gun geometry. Computational fluid dynamics analyses (CFD) were performed by determining two different data sets to examine the electric arc, fluid mechanics interaction in the gun and gas dynamics in the gas atomisation (GA) nozzle added to the continuation of the plasma part. Data sets were generated from the literature and Stat-Ease 360 software. Current intensity, volumetric flow rate, anode length and anode diameter were determined as variable parameters and their effects on the peak temperature, velocity and velocity vectors were analysed. It was observed that at constant current and increasing volumetric flow rate, the arc root formation increased the highest temperature level in the region where the arc root formation approached the anode exit section, while high current values shifted the arc root formation to the anode entrance section. While evaluating the analyses, optimisation was made on the data sets by considering the tungsten (W) addition process to be performed afterwards. At this stage, the most suitable parameter range was successfully determined, which enables the material with high melting temperature to be broken down and the broken material to be transported to the GA nozzle area by keeping the material at a temperature well above the melting point at approximately 15 000 K temperature levels.