Physical and technological features of mechanoactivation of powder particles formed during hydro-vacuum dispersion of metallic melts

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Abstract

A study has been conducted on the hydro-vacuum dispersion process of metal melts using gray cast iron SCh20 (in Russian nomencluture; 3.3–3.5C, 1.4–2.4Si, 0.7–1Mn, <0.15S, <0.2P in wt %)—an analogue of GG20. It has been revealed that the main factor conditioning the mechanoactivation of formed particles is their solidification in a fibrous non-equilibrium structural-tensioned state. This state is achieved by flattening and asymmetric twistedness of droplets that are detached from the liquid metal in the disperser under volumetric impact of shock-pulsating waves of hydraulic discharge. The degree of particle activation was found to depend exponentially on their dispersion and specific surface area. These parameters determine the degree of asymmetry of shear deformations and the amount of accumulated energy. In turn, the size dispersion and specific surface are significantly influenced by physical and technological factors such as the specific flow rate and pressure of injected water, the thickness and the elevation angle of the hydro shell of the vacuum diffusion funnel, the diameter of the dispersed melt jet passed through it, and its superheating temperature. The control of these parameters makes it possible to smoothly adjust the key ratio “liquid metal: water” and set up the dispersion process with the highest possible degree of size dispersion and activation of the resulting powder.

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About the authors

G. V. Jandieri

LEPL R. Dvali Institute of Machine Mechanics; Metallurgical Engineering and Consulting Ltd

Author for correspondence.
Email: gigo.jandieri@gmail.com
Georgia, 0186, Tbilisi, 0109, Tbilisi

D. V. Sakhvadze

Metallurgical Engineering and Consulting Ltd

Email: gigo.jandieri@gmail.com
Georgia, 0109, Tbilisi

B. G. Saralidze

LEPL Tavadze Institute of Materials Sciences and Metallurgy

Email: gigo.jandieri@gmail.com
Georgia, 0186, Tbilisi

G. D. Sakhvadze

Metal Powder Ltd.

Email: gigo.jandieri@gmail.com
Georgia, 0186, Tbilisi

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2. Fig. 1. General view of the main technological unit of the hydro-vacuum dispersion (HVD) installation during the commissioning of research equipment (a), its structural features (b) and wave dynamics of operation (c); 1 – cylindrical body; 2 – high–pressure water supply; 3 - cylindrical immersed in the body 1 (located concentrically) a pipe of smaller diameter and length with thickened walls 3 from below, narrowing its section; 4 – an annular channel (collector) formed between the outer body 1 and the inner pipe 3 for pumping water supplied through the channel 2; 5 – a semi–toroidal confuser with the function of intracorporeal reverse injection of water pumped into an annular collector (4), formed between the lower ends of the housing 1 and a pulp–forming Venturi 3-3 located inside it, with an outlet slit height of h; 6 - a ceramic nozzle immersed in the melt with a cylindrical channel 6 and with a conical head mating to the hydraulic rarefaction zone, with a nominal diameter – d; 7 – lower flange pair for fixing the nozzle (6) and sealing the housing (1); 7 – upper flange pair/roof for sealing the water–pressure annular collector (4); 8 - dispersion chamber, in which the shock–wave effect λ is carried out on the sucked melt; 8 – diffuser of the formed pulp; 9 - crankshaft nozzle with an ulpa-diverting cylindrical channel 9 for supplying pulp to the hydrocyclone sedimentation chamber and to sorting, and drying plants (not shown in the diagram).

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3. Fig. 2. Simplified hydromechanical scheme of the GWD process: y – linear velocity of displacement of melt particles, m/s; α – angle of attack of injected water on the jet of the sucked melt, deg; d1 – initial diameter of the sucked jet, mm; d2 – diameter of crimping after vortex-stretching action, mm; ω – angular velocity rotation, rad/s; ξ – the value of hydraulic resistance, kg/m3.

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4. Fig. 3. The surface of a particle with a cavitation ablation crater (a) and subsequently formed satellite spheroidal particles with a size of 0.1–1.3 microns (b).

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5. Fig. 4. Fragment of the vibration diagram of the main technological unit of the hydro-vacuum dispersion unit before (0→1) and after metal intake (1→2).

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6. Fig. 5. Morphology of the surface of a particle of the MF 20 melt solidified under conditions of angular shear deformation (a); relief of a particle with linear deformation-shear bands of a fibrous type (b); a cracked particle with a gas void core and a stratified shell of Fe3C cementite (c); a cracked particle with a dense layer detached from the outer shell the spheroidal core (d).

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7. Fig. 6. X-ray diffractogram of cast iron powder obtained by the GVD method.

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8. Fig. 7. Perforated imprints of cavitation pseudo-boiling before (a) and after their disclosure during the manufacture of the microplate (b).

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9. Fig. 8. Microstructure of the transition zone of a particle with a size of 500 microns with a section of a dense core and adjacent mesbands of angular deformation shear (a) and the dynamics of their propagation (b).

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10. Fig. 9. The effect of the initial melt temperature and the diameter of the suction nozzle on the dispersion of the resulting powder at water injection pressures of 12 (a) and 20 (b) bar.

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11. Fig. 10. Shape, microrelief (a) and morphology (b) of particles of gray cast iron powder SCH20 obtained in the mode of fine dispersion and amorphization.

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12. Fig. 11. X-ray diffractogram of GWD powder of cast iron (a) and copper extracted with its help (b).

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