Based on the preparation of TC4 powder under electrode induction melting gas atomization in this study, the concept of pre-breakup in the free-fall nozzle channel is innovatively proposed. The computational fluid dynamics method was used to simulate the pre-breakup process, and the effect of initial droplet size on the pre-breakup process was investigated. The pre-breakup process of TC4 discontinuous droplets was simulated using a Eulerian-Eulerian volume of fluid multiphase model and the Reynolds stress model. In addition, the Eulerian-Lagrangian discrete phase model and the unstable breakup model were employed to simulate the entire atomization process of the discontinuous droplets and predict the size of the powder particles. Some simulation results were verified based on experimental measurements. The results exhibit that the pre-breakup process of discontinuous droplets can be mainly divided into the formation of ellipsoidal droplets, the formation of annular disk-shaped stacked droplets, the formation of disk-shaped liquid films, and the breakage of the disk-shaped liquid film. In addition, the pre-breakup of small droplets or droplets with appropriately increased size can effectively prevent the broken droplets from hitting and adhering to the inner wall surface of the nozzle channel. Finally, with the increase of initial droplet size, the atomized powder particle size becomes gradually coarse, and the powder particle size distribution becomes gradually concentrated.

本研究在电极感应熔炼气体雾化下制备TC4粉末的基础上，创新性地提出了自由落体喷嘴通道预破碎的概念。采用计算流体动力学方法模拟预破碎过程，研究初始液滴尺寸对预破碎过程的影响。使用欧拉-欧拉体积流体多相模型和雷诺应力模型模拟 TC4 不连续液滴的预破碎过程。此外，采用欧拉-拉格朗日离散相模型和不稳定破碎模型模拟不连续液滴的整个雾化过程并预测粉末颗粒的尺寸。基于实验测量验证了一些模拟结果。结果表明，不连续液滴的预破碎过程主要分为椭圆形液滴的形成、环形盘状堆积液滴的形成、盘状液膜的形成和盘状液滴的破碎。液膜。此外，对小液滴或适当增大尺寸的液滴进行预破碎，可有效防止破碎的液滴撞击并粘附在喷嘴通道内壁表面。最后，随着初始液滴尺寸的增大，雾化粉体粒径逐渐变粗，粉体粒径分布逐渐集中。盘状液膜的形成，以及盘状液膜的破裂。此外，对小液滴或适当增大尺寸的液滴进行预破碎，可有效防止破碎的液滴撞击并粘附在喷嘴通道内壁表面。最后，随着初始液滴尺寸的增大，雾化粉体粒径逐渐变粗，粉体粒径分布逐渐集中。盘状液膜的形成，以及盘状液膜的破裂。此外，对小液滴或适当增大尺寸的液滴进行预破碎，可有效防止破碎的液滴撞击并粘附在喷嘴通道内壁表面。最后，随着初始液滴尺寸的增大，雾化粉体粒径逐渐变粗，粉体粒径分布逐渐集中。