Spatially Resolved Velocity Mapping of the Melt Plume During High-Pressure Gas Atomization of Liquid Metals

We present details of an image analysis algorithm designed specifically to determine the velocity of material in the melt plume during high-pressure, close-coupled gas atomization. Following high-speed filming (16,000 fps) pairs of images are used to identify and track dominant features within the plume. Due to the complexity of the atomization plume, relatively few features are tracked between any given pair of images, but by averaging over the many thousands of frames obtained during high-speed filming a spatially resolved map of the average velocity of material in the plume can be built up. Velocities in the plume are typically very low compared to that of the supersonic gas, being around 30 m s−1 on the margins of the plume where the melt interacts strongly with the gas and dropping to < 10 m s−1 in the center of the melt plume. Consequently, the efficiency of the atomizer in transferring kinetic energy from the gas to the melt is correspondingly very low, with this being estimated as being no more than 0.1 pct.