Multiphase model to predict particle size distributions in close-coupled gas atomization

A novel two-stage multiphase model is developed for close-coupled gas atomization by combining formulations available in the literature. Primary atomization is simulated using an Eulerian atomization model, and the outputs are used as inputs of a Lagrangian particle tracking approach to predict the particle size distribution resulting from secondary atomization. The results given by the primary atomization model are validated with published Direct Numerical Simulations (DNS) values and by comparison with experimental images of the spray, while the particle size distributions obtained are accurately fitted to a log-normal distribution, and with powder mean diameters showing good agreement with experimental data. The variation of powder characteristic diameters d10, d50, and d90 as a function of the gas-to-melt mass flow rate ratio follows correct trends, and the values of powder mean diameters d50 are correctly predicted by the model.