Ultrasonic Atomization as a Method for Testing Material Properties of Liquid Metals

Ultrasonic atomization is an object of steadily increasing interest from metal powder manufacturers, both for additive manufacturing and powder metallurgy. Based on the analysis of available theoretical studies, simulations and experiments, it was noted that the average particle size after atomization and the final particle size distribution depend on the process parameters (e.g., frequency, amplitude) and the parameters of the atomized fluid (e.g., viscosity, surface tension). The objective of this study is to evaluate the feasibility of using ultrasonic atomization to study the properties of liquid metals. It attempts to close a gap in existing knowledge in searching for a new, possibly simple and cost-effective method to study the properties of liquid metals and clarify the relationship between ultrasonic atomization parameters (amplitude, frequency, metal spill on vibrating surface) and obtained atomization results (average particle size, particle size distribution, atomization time). Utilizing numerical modeling as a methodology, especially the finite element method, the possibilities of using ultrasonic atomization as an instrument to determine properties of liquid metals were considered as an introduction to a series of real experiments. Modeling was applied to liquids with different properties, atomized at a chosen specific constant frequency and amplitude. The results of the simulation are in line with the current state of knowledge about ultrasonic atomization. However, in the existing studies available to the authors, there are no data that can be compared directly, but indirect comparisons confirmed the conclusions of the preliminary literature analysis. The relationship between viscosity and surface tension and the average size of the atomization processes obtained in the simulation of particles was demonstrated, thus providing a tool for the development of the presented concept: ultrasonic atomization as a research method. Research and simulation results led to the final conclusion: ultrasonic atomization can be applied to study the properties of liquid metals and this will be the subject of further research and experimentation.