This project is based on my MSc thesis, which investigates the secondary atomization and solidification behavior of molten metal droplets in a gas atomization process. The goal is to develop a robust CFD algorithm using the Eulerian-Lagrangian framework to simulate and validate the formation of fine metal powders — essential for applications like additive manufacturing.
During gas atomization, high-pressure gas jets disrupt a molten metal stream, breaking it into ligaments and then into fine droplets, which solidify into powders. This simulation pipeline models that phenomenon, with specific attention to:
- Primary breakup via Eulerian methods
- Secondary atomization and solidification using Lagrangian tracking
- Validation against experimental data
- Hybrid Eulerian-Lagrangian solver for multiphase modeling
- Implementation of:
- Taylor Analogy Breakup (TAB) model
- Kelvin-Helmholtz (KH) instability model
- Two-phase solidification model, including recalescence for small droplets
- Validation using droplet size and trajectory comparisons
- Dimensionless analysis using Reynolds, Weber, and Ohnesorge numbers
- The KH model provided the most accurate match with experimental results.
- The model accurately captured droplet breakup dynamics and solidification behavior.
- Recalescence observed in simulation confirms rapid phase change in small particles.
- Code and results are available in the repository.
Full thesis:
📘 Secondary Atomization and Solidification of Metal Melt in Gas Atomization (Politecnico di Torino)
Citation:
Abdollahi, H., Finotello, G., Misul, D.A. (2023). Secondary Atomization and Solidification of Metal Melt in Gas Atomization. Politecnico di Torino.
URL: https://webthesis.biblio.polito.it/29856
Hamed Abdollahi
MSc, Technical University of Eindhoven
Feel free to connect or collaborate!
Code and simulation setup of this project. Using OpenFOAM v22.12