On-Line, Real-Time Diagnostics of a Single Fluid Atomization System

A drop tube-Impulse Atomization technique was used to produce copper droplets. In this method, energy is transferred to a liquid by plunger movement resulting in spherical droplets emanating from orifices. A mathematical model of the evolution of droplet velocity and temperature at various heights for different sized droplets was developed. A two-color pyrometer, DPV-2000, and a shadowgraph were used to measure droplets radiant energy, diameter and velocity. The temperature values from the model were used to assess the two color pyrometer assumption over the temperature range of measurement. The DVP 2000 measurements were found to be dependent of droplet size wavelength and position of droplets below the atomizing nozzle. By calibrating the instrument for effective emissivity over the range of measurements, the thermal history of droplets may be recorded using a single color pyrometer approach

Heterogeneous nucleation of the primary phase in the rapid solidification of Al-4.5wt%Cu alloy droplet

International audienceThis paper reports on rapid solidification of Al-Cu alloys. A heterogeneous nucleation/growth model coupled with a thermal model of a falling droplet through a stagnant gas was developed. The primary undercooling as well as the number of nucleation points was compared with Al-Cu alloy droplets produced by Impulse Atomization (IA). Based on experimental results from Neutron Diffraction, secondary (eutectic) phases were obtained. Then, primary and secondary undercoolings were estimated using the metastable extensions of solidus and liquidus lines calculated by Thermo-Calc. Moreover, Synchrotron X-ray micro-tomography has been performed on Al-4.5wt%Cu droplets. The undercoolings are in good agreement. Results also evidence the presence of one nucleation point and are in agreement with the experimental observations. 1. Introduction Manufacturing of most metallic alloy products involves solidification at some stage. Mechanical properties of these products are generally related to their solidification microstructures. Depending on the final application of a product, a certain type of microstructure is more appropriate compared to another. For a product that requires directional properties, a microstructure of columnar grains is needed while isotropic properties are satisfied with an equiaxed structure. Generally, post-processing of the solidified materials is required to obtain the final product with desired properties. These post-solidification treatments are generally time-consuming and therefore increase the production cost without fully eliminating solidification related defects such as segregation. Therefore, it is important to understand all the dynamics involved in the formation of solidification microstructures in order to control the properties of the final products. As dendrites growth from an undercooled melt depends a great deal on the nucleation undercooling. Therefore, determination of undercooling and the resulting growth rate, recalescence, microsegregation/phase fraction and grain size is very important. Al-Cu alloys (4.5, 5, 10 and 17 wt% Cu) have been produced by IA and the last three compositions were analysed in our previous papers [1, 2]. IA is a single fluid atomization technique that is capable of producing droplets of controlled size having a relatively narrow distribution and a predictable cooling rate. The alloys (350 to 450g) were melted in a graphite crucible by means of an induction furnace and atomized at 850ºC in an almost oxygen free chamber (10ppm) under Nitrogen, Helium or Argon atmospheres. The atomized droplets rapidly solidify during their fall by losing heat to th

The S shape of a granular pile in a rotating drum

The shape of a granular pile in a rotating drum is investigated. Using Discrete Elements Method (DEM) simulations we show that the "S shape" obtained for high rotation speed can be accounted for by the friction on the end plates. A theoretical model which accounts for the effect of the end plates is presented and the equation of the shape of the free surface is derived. The model reveals a dimensionless number which quantifies the influence of the end plates on the shape of the pile. Finally, the scaling laws of the system are discussed and numerical results support our conclusions

Evolution of the dendritic morphology with the solidification velocity in rapidly solidified Al- 4.5wt.%Cu droplets

International audienceThe microstructure morphology of Al-4.5wt.%Cu droplets formed by the Impulse Atomization technique is investigated. Three-dimensional reconstructions by synchrotron X-ray micro-tomography of several droplets reveal different morphologies in droplets of similar diameter and produced in the same batch. Moreover, microstructural features also indicate that the development of the dendrite arms occurs in some droplets along crystallographic axes instead of the usual directions observed in conventional casting for the same alloy. It has been observed that such an unusual growth direction of the dendrites is directly related to the solidification velocity. We underpin these results by carrying out comparisons with a solidification model. Predictions are used to discuss the change of dendrite growth direction, as well as the existence of a dendrite growth direction range for a given type of droplets. In addition, the effect of the droplet size and the cooling gas on the dendrite growth direction range observed experimentally is also investigated by using the model. 1. Introduction Rapid solidification techniques have been developed as they enable to obtain a wide variety of structures which cannot be formed under conventional solidification processes [1]. They differ by the way to form the liquid as a strip or a droplet and by the method of heat extraction. Atomization techniques are used to make metallic powders which are used for making a desired object by pressing or by sintering [2]. The liquid metal generated as a stream breaks up into droplets by Rayleigh-Plateau instability, which subsequently solidify in a much colder medium. In the Impulse Atomization (IA) technique the liquid is pushed through a nozzle plate to form the liquid streams [3]. In order to deepen the understanding of the microstructure formation in the droplets, synchrotron X-ray micro-tomography was carried out at the European Synchrotron Radiation Facility (ESRF, Grenoble, France). Three-dimensional reconstructions of a large number of droplets were obtained, enabling the inner microstructure of the droplets to be statistically analysed for the first time. In a previous paper, we showed that four distinct morphologies could be identified in droplets of the same size and from the same batch [4]. Such a range of morphologies can be linked to a range of solidification velocities for the droplets. Indeed, while Rappaz and co-workers highlighted the <100

Materials Research in Microgravity 2012

Reducing gravitational effects such as thermal and solutal buoyancy enables investigation of a large range of different phenomena in materials science. The Symposium on Materials Research in Microgravity involved 6 sessions composed of 39 presentations and 14 posters with contributions from more than 14 countries. The sessions concentrated on four different categories of topics related to ongoing reduced-gravity research. Highlights from this symposium will be featured in the September 2012 issue of JOM. The TMS Materials Processing and Manufacturing Division, Process Technology and Modeling Committee and Solidification Committee sponsored the symposium

Effects of communication and utility-based decision making in a simple model of evacuation

We present a simple cellular automaton based model of decision making during evacuation. Evacuees have to choose between two different exit routes, resulting in a strategic decision making problem. Agents take their decisions based on utility functions, these can be revised as the evacuation proceeds, leading to complex interaction between individuals and to jamming transitions. The model also includes the possibility to communicate and exchange information with distant agents, information received may affect the decision of agents. We show that under a wider range of evacuation scenarios performance of the model system as a whole is optimal at an intermediate fraction of evacuees with access to communication.Comment: 9 pages, 9 figure

Dendrite growth in undercooled Al-rich Al-Ni melts measured on Earth and in Space

The dendrite growth velocity in Al₇₅Ni₂₅ melts has been measured in a containerless procedure as a function of undercooling using an electromagnetic levitation technique both in the Earth laboratory and in Space on board the International Space Station. The growth shows an anomalous behavior inasmuch as the growth velocity decreases with increasing undercooling, confirming previous experiments on Earth. Within the scatter of experimental data, results obtained on Earth and in Space do not show significant differences. Thus, convection effects as the origin of the anomalous growth characteristics can be excluded. However, high-speed video recording exhibits multiple nucleation events in front of the growing solid-liquid interface. This effect is identified as the origin of the anomalous dendrite growth characteristics in undercooled melts of Al-rich Al-Ni melts