PhD on Advanced Atomization for Metal Powder Production

at  TU Eindhoven

JOB DESCRIPTION

We are looking for a talented PhD candidate to join our research team focused on advanced atomization processes for producing high-quality metal powders. This project will combine physical experiments and Computational Fluid Dynamics (CFD) modeling to deepen our understanding of the atomization process—a crucial step in powder metallurgy (PM) and additive manufacturing (AM).

PROJECT DESCRIPTION

The production of metal powders for PM and AM requires high sphericity, uniform particle distribution, and optimal size characteristics. Molten metal atomization is the key process that transforms molten material into fine, spherical particles using high-velocity gas streams. This project aims to develop an experimentally validated CFD model for this process, advancing the understanding of the physical and chemical mechanisms involved in close-coupled gas atomization (CCGA).The overall objective of this study is the development of the experimentally validated CFD model for molten metal atomization. To pursue the overall objective, in this project we aim to:

• Goal 1 Develop a gas atomization CFD model

At TU/e, a numerical framework describing the molten metal droplet behavior during gas atomization is under development. This model is crucial as it provides a theoretical basis for understanding and predicting the behavior of molten metal during atomization. The model must include: (i) primary breakup, (ii) secondary breakup, (iii) coupling between primary and secondary breakups.

• Goal 2 Perform digital inline holography (DIH) experiments

To validate and refine our CFD model, we need experimental data of spray and droplet characteristics. At Technion, digital inline holography experiments on close-coupled gas atomization (CCGA) have been performed using water and air. The setup and experimental technique will be used to carry out atomization experiments of glycerol/water mixtures (change in viscosity) and solutions with surfactants (change in surface tension). These liquids with different physical properties are used to mimic the typical properties of molten metal. The experiments will provide critical data on velocity and droplet size distributions, as well as the number of droplets per unit volume and their spatial distribution in the spray.

• Goal 3 Validate the gas atomization model with experimental results

Validation is essential to ensure the CFD model’s accuracy and reliability. The gas atomization CFD model developed at TU/e will be validated using the experimental results obtained from DIH at Technion. This validation will confirm the model’s ability to accurately simulate the atomization process.

JOB REQUIREMENTS

Talented, enthusiastic candidates with excellent analytical and communication skills holding a master’s degree in mechanical engineering, Chemical Engineering or related fields are encouraged to apply. The following skillsets are required:

• Strong background in fluid dynamics, heat transfer, and computational modeling (CFD) with a proven particle/flow simulation experience in multiphase flows
• Experience with Open Foam is beneficial
• Experience with experimental techniques such as digital holography and/or PIV is beneficial
• Experience to work in a multi-disciplinary team of researchers
• Fluent in spoken and written English.

• Develop a CFD model for gas atomization: Work on a numerical framework that simulates molten metal breakup during atomization, covering primary and secondary breakup processes.
• Conduct digital inline holography (DIH) experiments: Design and perform experiments using surrogate liquids to capture critical data on spray dynamics, droplet sizes, and velocities.
• Validate the CFD model: Use experimental results to validate and refine the CFD model, ensuring its accuracy in predicting the atomization process.
• Collaborate with Technion- Israel Institute of Technology: Participate in cross-institutional research, utilizing both experimental and computational techniques to enhance the project’s outcomes.