Simulation Study of Smoothed Particle Hydrodynamics (SPH) Method in Plasma Spheroidization of W-Ni-Fe Ternary Alloys

doi:10.11900/0412.1961.2020.00381

Acta Metall Sin

2021, Vol. 57

Issue (2): 247-256 DOI: 10.11900/0412.1961.2020.00381

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Simulation Study of Smoothed Particle Hydrodynamics (SPH) Method in Plasma Spheroidization of W-Ni-Fe Ternary Alloys

HOU Yubai¹^,²^,³, YU Yueguang²(

), GUO Zhimeng¹

^1.Institute for Advanced Materials and Technology, University of Science and Technology Beijing, Beijing 100083, China
^2.BGRIMM Technology Group, Beijing 100160, China
^3.BGRIMM Advanced Materials Science & Technology Co. , Ltd. , Beijing 102206, China

Cite this article:

HOU Yubai, YU Yueguang, GUO Zhimeng. Simulation Study of Smoothed Particle Hydrodynamics (SPH) Method in Plasma Spheroidization of W-Ni-Fe Ternary Alloys. Acta Metall Sin, 2021, 57(2): 247-256.

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Abstract

Metal additive manufacturing three-dimensional printing technology is widely used in the manufacturing industry. This technology is an important scientific and technological achievement in the field of world-class manufacturing, and it has influenced and changed the ways of production, which has brought great changes in the manufacturing field. The plasma spheroidization process can provide a better rate of spheroidization for refractory metals. Smoothed particle hydrodynamics (SPH) is a mesh-less Lagrangian method to simulate a flow field and enable heat transfer. This method has shown great potential for replacing the traditional numerical methods and has been successfully used to simulate the collision and fusion process of metal droplets during plasma spheroidization. In this study, the SPH technique has been employed to simulate the collision and fusion processes of multiple metal droplets of a W-Ni-Fe ternary alloy in plasma spheroidization with the consideration of the effect of surface tension. The spheroidization process has been visualized with fluid evolution in terms of the flow field and temperature distribution. A high spheroidization quality is found in a system with the a high amount of tungsten, small tungsten particle size, high processing environment temperature, and large Marangoni force. To check the simulation results, spheroidization experiments have been conducted using the following raw materials: tungsten powder with an average particle size of 1.5 μm, nickel powder with an average particle size of 4.1 μm, and iron powder with an average particle size of 2.4 μm. The raw materials were mixed with a mass ratio of W∶Ni∶Fe=90∶7∶3 and then spheroidized at 8000^oC. The achieved ternary alloy powder has high sphericity and dense internal structure. The flowability of the powders is 11.62 s/50 g. The apparent density is 10.66 g/cm³. The resulting products show high precision and good efficiency. The experiments confirm the consistency of SPH simulation. The simulation results can be used to guide development in the fabrication process of the spheroidized powder of refractory metals, such as tungsten.

Key words: smoothed particle hydrodynamics (SPH) metal droplet fusion plasma spheroidization

Received: 22 September 2020

ZTFLH:

TG146.4

Fund: National Key Research and Development Program of China(2017YFB0305800)

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	Yubai HOU
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https://www.ams.org.cn/EN/10.11900/0412.1961.2020.00381 OR https://www.ams.org.cn/EN/Y2021/V57/I2/247

Fig.1 Schematic of smoothed particle hydrodynamics (SPH) model for W-Ni-Fe ternary alloy

Table1 The physical property parameters of materials

Table 2 The parameters of different models

Fig.2 Simulation results under different collision conditions by using SPH

Fig.3 Simulation results for W-Ni-Fe ternary alloy after droplet fusion under different mass ratios of W∶Ni∶Fe (models 1-3)

Fig.4 Simulation results for W-Ni-Fe ternary alloy after droplet fusion under different temperatures (models 4-6)

Fig.5 Simulation results for W-Ni-Fe ternary alloy after droplet fusion under different diameters of W (models 7-9)

Fig.6 Simulation results for W-Ni-Fe ternary alloy after droplet fusion under different Marangoni coefficients (models 10-12)

Table 3 The merging data of W-Ni-Fe droplet fusion for different models

Fig.7 The spheroidization ratio and compactness curves obtained by an interpolation method

Fig.8 SEM images of W-Ni-Fe ternary alloy before (a) and after (b) spheroidization

Fig.9 SEM image and corresponding EDS analyses for W-Ni-Fe ternary alloy after spheroidization

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