Analysis of brush-molten metal interaction in brush atomizers: a CFD approach

Abstract

Optimizing the efficiency of metal powder production through brush atomization necessitates a comprehensive understanding of the interaction between the brush bristles and the molten metal, as well as its consequential effects on the fragmentation of the melt. Thus this study presents Computational Fluid Dynamics (CFD) models of the brush-melt interplay during the atomization of molten metals. The volume-of-fluid method was used to examine the various stages of melt fragmentation, from when the melt is discharged to when it settles on the brush bristles. The results revealed that the first breakup occurred close to the discharge orifice due to aerodynamic instability and fell within 13 < ${\mathit{\text{We}}}_G$< 40.3. The nature of this breakup depends on the brush speed, bristle length, bristle diameter, brush density, and melt properties. A second breakup was observed when the melt contacted the rotating bristles. The melt bridges formed between two or more bristles due to attractive forces between the closely packed bristles induced by the capillary force of the melt and the surface tension of the meniscus surface are also overcome due to brush rotation. These results are in agreement with the experimental observations and are therefore sufficient for demonstrating the system.

Keywords:

• Brush
• atomization
• metal
• powder
• modeling
• numerical

REVIEWING EDITOR:

• Dr Pham D T
• University of Birmingham
• Birmingham
• UNITED KINGDOM of GREAT BRITAIN and NORTHERN IRELAND

SUBJECTS:

• Mechanical engineering design
• fluid mechanics
• mechanical engineering
• materials science
• manufacturing engineering
• production engineering

Authors contribution

Onwuka O.S.: Conceptualization, methodology, writing the original draft. Unachukwu G.O.: Supervision, Writing – review and editing. Nwanya S.C.: Supervision, reviewing, methodology.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Data availability statement

All data generated or analyzed during this study are included in this manuscript.

Additional information

Notes on contributors

Osinachi Stanley Onwuka

Osinachi Stanley Onwuka is a Lecturer at Michael Okpara University of Agriculture, Umudike, Nigeria. His research interests include: metal powder atomization, material synthesis, optimization and modeling of systems. Onwuka boasts a remarkable academic track record, featuring numerous publications and patented innovations.

Godwin Ogechi Unachukwu

Godwin Ogechi Unachukwu is a Professor in the field of Energy and Power at University of Nigeria, Nsukka. His expertise extends to areas such as energy efficiency, renewable energy, and energy policy. Professor Unachukwu is a beacon, inspiring the next generation of engineers and researchers.

Stephen Chijioke Nwanya

Stephen Chijioke Nwanya is a Professor at the University of Nigeria, Nsukka, whose contributions extend across education, research, and professional practice. He earned a Doctor of Philosophy Degree (Ph.D.) in Tecnologie Chimiche ed Energetiche at Universita’ Degli Studi di Udine, Italy. His interests include engineering management, energy modeling, and optimization.