Melt film formation and disintegration during novel atomization process

Hybrid atomization is a new powder-making method and can produce economically very fine, clean, spherical tin alloy powders with average particle size about 10μm and narrow size distributions. The key concept of hybrid atomization is to control the liquid film formation on disk for fine powder production. Low-pressure gas atomization was utilized to promote the formation of a very thin stable liquid film before centrifugal breakup and give a better preparation for the final disintegration of melts. Besides the breakup ability of the rotating atomizer, the characteristics of liquid film on rotating disk affect the atomization mechanism and results remarkably. The main disintegration mode of melt is the breakup type of liquid film, which depends on the film instability and the atomization ability of the rotating disk. On the other hand, the mean powder size relates closely to the film thickness. The powder size distribution is mainly controlled by the atomization mode and the stability, flow type of liquid film on the rotating disk. A very thin, stable liquid film with long ligaments and a small pitch in LF mode results in very fine uniform tin alloy powders.