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Numerical investigation of fine sand removal in vortex-enhanced spiral pipeline separators via coupled CFD-DEM simulation 基于CFD-DEM耦合模拟的涡流增强螺旋管道分离器细砂去除数值研究
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-30 DOI: 10.1016/j.powtec.2025.121702
Yuting Zhu , Yu Lu , Yiquan Wu , Junyao Zhang , Gong Chen , Guanhua Zhang , Zhigen Wu
{"title":"Numerical investigation of fine sand removal in vortex-enhanced spiral pipeline separators via coupled CFD-DEM simulation","authors":"Yuting Zhu ,&nbsp;Yu Lu ,&nbsp;Yiquan Wu ,&nbsp;Junyao Zhang ,&nbsp;Gong Chen ,&nbsp;Guanhua Zhang ,&nbsp;Zhigen Wu","doi":"10.1016/j.powtec.2025.121702","DOIUrl":"10.1016/j.powtec.2025.121702","url":null,"abstract":"<div><div>In this study, a coupled numerical simulation approach integrating Computational Fluid Dynamics (CFD) for continuous fluids and the Discrete Element Method (DEM) for particulate phases was employed to investigate the hydrodynamics of sand-laden wastewater within a spiral separator. The effects of varying inlet velocities on the distribution and separation efficiency of sand particles across different size ranges were examined. To validate the numerical model, experimental tests were conducted using the spiral separator to treat municipal wastewater containing fine sand particles (&lt;200 μm), with the simulation results benchmarked against the experimental data. The findings demonstrated that the spiral separator exhibited pronounced flow-guiding and swirling effects, resulting in efficient particle separation. The optimal flow velocity for effective sand particle separation was determined to be 0.25 m/s. Notably, particles sized 150–200 μm demonstrated superior separation at lower flow velocities, while increasing the inlet velocity significantly enhanced the separation efficiency for particles in the 50–100 μm size range. The proposed spiral separator design achieved low hydraulic losses and high separation efficiency, establishing a novel framework for low-resistance, high-performance sand removal in municipal wastewater treatment.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121702"},"PeriodicalIF":4.6,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264617","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Experimental investigation of the roasting behaviour and phase transformations in a zinc sulfide concentrate 某硫化锌精矿焙烧行为及相变试验研究
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-30 DOI: 10.1016/j.powtec.2025.121714
X. Wen , J. Chen , M. Ng , L.A. Ushkov , E. Jak
{"title":"Experimental investigation of the roasting behaviour and phase transformations in a zinc sulfide concentrate","authors":"X. Wen ,&nbsp;J. Chen ,&nbsp;M. Ng ,&nbsp;L.A. Ushkov ,&nbsp;E. Jak","doi":"10.1016/j.powtec.2025.121714","DOIUrl":"10.1016/j.powtec.2025.121714","url":null,"abstract":"<div><div>The present study investigates the proportion of phases in zinc calcines produced by statically roasting zinc sulfide concentrate at temperatures between 600 and 950 °C and varying roasting times. Utilizing an integrated analytical approach combining Electron Probe X-ray Microanalysis (EPMA) with Wavelength Dispersive Spectroscopy (WDS) and Automated Mineralogy Analysis (AMA), AMICS, with Energy Dispersive Spectroscopy (EDS), a comprehensive mineralogical database suitable for the characterisation of zinc sulfide concentrate and calcines was developed. The present study addresses limitations of traditional characterisation methods by providing detailed, quantitative insights into the calcine structure, focusing on the proportion of key phases such as zincite, spinel (zinc ferrite), willemite (zinc silicates), and residual silicates/sulfides. The zincite content of the calcines displayed a non-linear relationship with temperature, peaking between 750 and 850 °C; lower roasting temperatures led to greater formation of the zinc ferrite phase, while higher temperatures led to greater formation of the zinc silicate phase, which have negative consequences for the leaching and leachate separation processes respectively. This work provides crucial understanding for optimizing zinc processing conditions by detailing the factors influencing zinc ferrite and silicate formation.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121714"},"PeriodicalIF":4.6,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264614","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Preparation of recycled zirconia powders for use in esthetic dental restorations by wet ball milling technique 用湿球磨技术制备美观牙体修复用再生氧化锆粉
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-29 DOI: 10.1016/j.powtec.2025.121688
Hui Yang , Kenta Yamanaka , Manami Mori , Shunichi Shishido , Juan Ramón Vanegas Sáenz , Keisuke Nakamura , Guang Hong
{"title":"Preparation of recycled zirconia powders for use in esthetic dental restorations by wet ball milling technique","authors":"Hui Yang ,&nbsp;Kenta Yamanaka ,&nbsp;Manami Mori ,&nbsp;Shunichi Shishido ,&nbsp;Juan Ramón Vanegas Sáenz ,&nbsp;Keisuke Nakamura ,&nbsp;Guang Hong","doi":"10.1016/j.powtec.2025.121688","DOIUrl":"10.1016/j.powtec.2025.121688","url":null,"abstract":"<div><div>This study aimed to optimize ball milling conditions for preparing recycled zirconia powder (RZP) for esthetic dental restorations. Initial RZP and four ball milling groups, including 3-WM (3 mm beads, wet milling), 3-DM (3 mm beads, dry milling), 5-WM (5 mm beads, wet milling), and 5-DM (5 mm beads, dry milling), were characterized. The sintered samples were compared with commercial zirconia in terms of the microstructure, transmittance, translucency parameter (<em>TP</em><sub><em>00</em></sub>), color difference (<em>ΔE</em><sub><em>00</em></sub>), density, hardness, fracture toughness, and biaxial flexural strength. Smaller beads enabled more effective RZP refinement. Wet milling proved superior to dry milling in achieving finer particles and reducing crystal defects. Recycled zirconia sintered from 3-WM powders, particularly after 3 h of milling, exhibited microstructure, optical, and mechanical properties comparable to commercial zirconia (<em>ΔTP</em><sub><em>00</em></sub> and <em>ΔE</em><sub><em>00</em></sub> below perceptibility threshold; strength &gt;800 MPa). Initial RZP and 3-DM samples showed microstructural flaws, leading to poorer mechanical and esthetic outcomes.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121688"},"PeriodicalIF":4.6,"publicationDate":"2025-09-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217282","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
The impact of microwave drying technology on the drying kinetics of phosphate ore 微波干燥技术对磷矿干燥动力学的影响
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-27 DOI: 10.1016/j.powtec.2025.121695
Pengzhi Luo , Guangjin Wang , Shujian Li , Menglai Wang , Yashan Li , Mamdouh Omran , Zhaoyu Ma , Ju Tang , Fan Zhang , Guo Chen
{"title":"The impact of microwave drying technology on the drying kinetics of phosphate ore","authors":"Pengzhi Luo ,&nbsp;Guangjin Wang ,&nbsp;Shujian Li ,&nbsp;Menglai Wang ,&nbsp;Yashan Li ,&nbsp;Mamdouh Omran ,&nbsp;Zhaoyu Ma ,&nbsp;Ju Tang ,&nbsp;Fan Zhang ,&nbsp;Guo Chen","doi":"10.1016/j.powtec.2025.121695","DOIUrl":"10.1016/j.powtec.2025.121695","url":null,"abstract":"<div><div>To address the technical bottlenecks of traditional phosphate drying methods, including high energy consumption and unstable product quality, this paper proposes an energy-saving dehydration method based on microwave radiation. The effects of initial moisture content, initial mass, and microwave power on the drying kinetics of phosphate ore were investigated. The results show that microwave power, moisture content, and initial mass are positively correlated with drying rate. Four kinetic models were constructed to analyze the drying process of phosphate ore under microwave action, including Quadratic, Page, Modified Page, and Wang-Singh models. The results indicate that the Modified Page model has a higher fitting accuracy. Fourier Transform Infrared (FT-IR) spectroscopy analysis shows that after microwave treatment, the intensity of the infrared absorption peak corresponding to water in the sample significantly decreased, proving effective removal of moisture. Additionally, no shift was observed in other characteristic absorption peaks in the spectra, confirming that the treatment process did not alter the primary chemical composition of the sample. This breakthrough overcomes the limitations of traditional thermal drying, which often leads to the destruction of the mineral lattice. The activation energy (13.1872 g/W) determined from the Arrhenius equation reveals the mechanism of moisture desorption during microwave drying. This study provides both theoretical and empirical support for the application of microwave drying technology in the field of phosphate mineral processing.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121695"},"PeriodicalIF":4.6,"publicationDate":"2025-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Continuum model for the numerical simulation of the sedimentation process of two immiscible non-Newtonian suspensions confined in an annulus 连续体模型的数值模拟沉降过程的两个不混相非牛顿悬浮物限制在一个环空
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121672
Allan Barbosa Geoffroy Motta , Elessandre Alves de Souza , Luiz Augusto da Cruz Meleiro , Luís Américo Calçada , Cláudia Miriam Scheid
{"title":"Continuum model for the numerical simulation of the sedimentation process of two immiscible non-Newtonian suspensions confined in an annulus","authors":"Allan Barbosa Geoffroy Motta ,&nbsp;Elessandre Alves de Souza ,&nbsp;Luiz Augusto da Cruz Meleiro ,&nbsp;Luís Américo Calçada ,&nbsp;Cláudia Miriam Scheid","doi":"10.1016/j.powtec.2025.121672","DOIUrl":"10.1016/j.powtec.2025.121672","url":null,"abstract":"<div><div>The sedimentation process in a single suspension was broadly studied in many previous works. In the annular region of oil wells, the presence of the drilling fluid is common, which contains solid particles acting as a weighting agent. Additionally, there is a second confined fluid, known as a washer, that has the function of avoiding contamination of cement paste by the drilling fluid. The washer is heavier than the drilling fluid and may also have solid particles in its composition. The batch sedimentation of two immiscible suspensions is yet now well known. Here we employed a continuum model for the sedimentation in one suspension, which was previously validated with experiments and was able to obtain the solids concentration profile over time. We extended the model to the case with two immiscible fluids. The domain was discretized using the finite volume method. The problem was evaluated at a real well scale. The results showed that the presence of the second fluid may significantly alter the sedimentation process of the light suspension and depend on the fluid base type, as well as the difference in the suspensions’ properties. Formation of sediment may be observed above the interface between the suspensions, depending on the heavy suspension rheology and solids concentration. The rheological parameters had a key role in the process. Also, we studied the cases with different temperature conditions, as the model may account for the temperature effect locally in the rheological behavior of the suspensions.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121672"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217208","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Experimental study on the coupled motion of Flip-flow screen plate and granular materials based on target tracking technology 基于目标跟踪技术的转流筛板与颗粒物料耦合运动实验研究
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121676
Ningning Xu , Long Cheng , Guofeng Zhao , Sanpeng Gong , Xinwen Wang , Junkai Fan
{"title":"Experimental study on the coupled motion of Flip-flow screen plate and granular materials based on target tracking technology","authors":"Ningning Xu ,&nbsp;Long Cheng ,&nbsp;Guofeng Zhao ,&nbsp;Sanpeng Gong ,&nbsp;Xinwen Wang ,&nbsp;Junkai Fan","doi":"10.1016/j.powtec.2025.121676","DOIUrl":"10.1016/j.powtec.2025.121676","url":null,"abstract":"<div><div>The flip-flow screen is widely applied in dry deep screening processes across various industrial sectors. However, limitations in understanding the motion mechanisms of large-deformation screen plates and material particle groups hinder its further optimization and broader application. Therefore, an experimental platform was constructed to observe the coupled motion, utilizing high-speed imaging and target tracking algorithms to monitor the motion of both materials and the screen plate. The accuracy of the tracking results was validated through comparison with acceleration measurement system data. The study identified the evolutionary patterns of coupled motion states under varying driving frequencies. By analyzing the displacement, velocity, and acceleration of both particles and the screen plate, it was revealed the mechanisms underlying these different motion states. Additionally, the effects of material load and screen tension on the evolution of particle motion states were examined, clarifying the regulation methods of coupled motion states. Results indicate that with a material load of 4 kg and a driving amplitude of 6 mm, within a driving frequency range of 1.5 Hz to 15 Hz, the material particles and the screen plate sequentially exhibit relative static, synchronous periodic motion, period-doubling motion, chaotic motion, and inert motion. Among these states, chaotic motion promotes greater particle activity, benefiting material loosening and segregation. Within the 6 Hz to 15 Hz driving frequency range, reducing the material load or increasing screen tension facilitates the occurrence of chaotic motion. These findings provide valuable insights for the improved application and optimization of flip-flow screens.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121676"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217210","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
TurboPSD prediction framework: Utilizing multivariable temporal dynamics for precise grinding production PSD (particle size distribution) estimates TurboPSD预测框架:利用多变量时间动态精确研磨生产PSD(粒度分布)估计
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121659
Yunfeng Li , Jingjing Li , Chengfang Yuan , Di Wu , Sida Liu , Zongyan Zhou , Caibin Wu , Li Ling
{"title":"TurboPSD prediction framework: Utilizing multivariable temporal dynamics for precise grinding production PSD (particle size distribution) estimates","authors":"Yunfeng Li ,&nbsp;Jingjing Li ,&nbsp;Chengfang Yuan ,&nbsp;Di Wu ,&nbsp;Sida Liu ,&nbsp;Zongyan Zhou ,&nbsp;Caibin Wu ,&nbsp;Li Ling","doi":"10.1016/j.powtec.2025.121659","DOIUrl":"10.1016/j.powtec.2025.121659","url":null,"abstract":"<div><div>Population Balance Model (PBM), most commonly used model for grinding dynamics, has been characterized by large errors in the prediction of multiple independent variables. To address these limitations, we propose a novel framework, TurboPSD, which leverages artificial intelligence models to overcome the lack of flexibility and improve forecasting performance. For the single-fill case, the framework is capable of learning the temporal dynamics between grit size and productivity, achieving a minimum mean squared error of just 0.06%, significantly outperforming the PBM approach, which exhibits an MSE of 11.86%. Furthermore, we extend the framework to multi-fill scenarios by incorporating fill amount as an additional feature. Compared to the PBM’s MSE of 38.08%, the framework demonstrates a substantial improvement, reducing the MSE to 0.26%. Experimental results confirm that TurboPSD Prediction Framework surpasses PBM approaches in terms of accuracy, robustness, and efficiency, demonstrating strong potential for widespread application in mineral processing industry.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121659"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227772","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Particle image velocimetry measurement of the wake of a particle with a uniaxial through-hole placed in a uniform flow 粒子图像测速法测量在均匀流动中带单轴通孔的粒子尾迹
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121638
K. Takamure , D. Kobayashi , T. Uchiyama , T. Degawa
{"title":"Particle image velocimetry measurement of the wake of a particle with a uniaxial through-hole placed in a uniform flow","authors":"K. Takamure ,&nbsp;D. Kobayashi ,&nbsp;T. Uchiyama ,&nbsp;T. Degawa","doi":"10.1016/j.powtec.2025.121638","DOIUrl":"10.1016/j.powtec.2025.121638","url":null,"abstract":"<div><div>As a significant contributor to drag and vibration, the wake created when an object is placed in a fluid flow or moves within a fluid has been extensively investigated. However, studies investigating the effects of through-holes are limited. Therefore, this study addresses this limitation by leveraging three-dimensional particles with uniaxial through-holes, which produce an axisymmetric jet that interacts with the wake in a fundamentally different manner. In this study, the wake behind a particle with a through-hole along its center axis was analyzed using particle image velocimetry in a uniform flow. The particle had a diameter of <span><math><mrow><mi>d</mi><mo>=</mo><mn>25</mn><mo>.</mo><mn>4</mn><mspace></mspace><mi>mm</mi></mrow></math></span>, with the through-hole diameter <span><math><msub><mrow><mi>d</mi></mrow><mrow><mi>h</mi></mrow></msub></math></span> varying by up to 15 mm, corresponding to a diameter ratio <span><math><mrow><mi>γ</mi><mo>=</mo><msub><mrow><mi>d</mi></mrow><mrow><mi>h</mi></mrow></msub><mo>/</mo><mi>d</mi><mo>≤</mo><mn>0</mn><mo>.</mo><mn>59</mn></mrow></math></span>. The uniform flow velocity was set to 3.6 m/s, resulting in a Reynolds number of approximately 6000. The results revealed that the flow structure behind the particle was significantly influenced by the diameter ratio <span><math><mi>γ</mi></math></span>. As <span><math><mi>γ</mi></math></span> increased, the jet flow from the through-hole intensified and surpassed the freestream velocity for <span><math><mrow><mi>γ</mi><mo>=</mo><mn>0</mn><mo>.</mo><mn>24</mn><mo>,</mo><mn>0</mn><mo>.</mo><mn>35</mn></mrow></math></span>. The reverse flow region behind the particle decreased with increasing <span><math><mi>γ</mi></math></span>, leading to the formation of distinct vortex structures owing to the interaction between the separated shear layer and through-hole jet. For a smaller <span><math><mi>γ</mi></math></span>, a pair of vortices formed along the separated shear layers and another pair on both sides of the through-hole jet. Conversely, the shear-layer vortices diminished as <span><math><mi>γ</mi></math></span> increased, whereas the through-hole jet vortices elongated downstream. At <span><math><mrow><mi>γ</mi><mo>=</mo><mn>0</mn><mo>.</mo><mn>59</mn></mrow></math></span>, only the shear-layer vortices remained closely attached to the surface of the particle. These findings offer valuable insights into wake control using through-hole modifications and enhance our understanding of shear layer and jet interactions in bluff-body wakes.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121638"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217283","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Particle size-dependent solidification heterogeneity: Simulation and experimental decoupling of gas-atomized Ni-based superalloy powders 颗粒尺寸依赖性凝固不均匀性:气雾化镍基高温合金粉末的模拟与实验解耦
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121658
Junkang Wu , Yang Huang , Yun Tan , Jialiao Zhou , Jian Yao , Liming Tan , Zi Wang , Lan Huang , Feng Liu
{"title":"Particle size-dependent solidification heterogeneity: Simulation and experimental decoupling of gas-atomized Ni-based superalloy powders","authors":"Junkang Wu ,&nbsp;Yang Huang ,&nbsp;Yun Tan ,&nbsp;Jialiao Zhou ,&nbsp;Jian Yao ,&nbsp;Liming Tan ,&nbsp;Zi Wang ,&nbsp;Lan Huang ,&nbsp;Feng Liu","doi":"10.1016/j.powtec.2025.121658","DOIUrl":"10.1016/j.powtec.2025.121658","url":null,"abstract":"<div><div>The microstructural uniformity of nickel-based superalloy powders for additive manufacturing has been recognized as a critical factor influencing the performance of built components. However, the particle-size-dependent solidification mechanisms during gas atomization remain poorly understood. In this study, the temperature fields and solidification histories of droplets with varying diameters were reconstructed through coupled thermo-fluid dynamics simulations. Combined with multi-scale characterization techniques, the effects of particle size on solidification structure, elemental segregation behavior, and grain structure were systematically investigated. The results revealed that cooling rate decreased with increasing particle size. Fine powders exhibited a cellular solidification structure due to rapid cooling, whereas coarse powders developed coarser dendritic morphologies, with the secondary dendrite arm spacing following a power-law relationship with particle size. In terms of solute segregation, positive segregation of Nb and Ti was observed in larger particles under near-equilibrium diffusion conditions, while Mo exhibited negative segregation due to diffusion limitations. Rapid solidification in smaller particles led to solute trapping and the formation of non-equilibrium microstructures. Grain structure analysis showed that smaller particles contained fewer but larger grains, whereas larger particles exhibited a multi-scale microstructure composed of both equiaxed and columnar dendrites. This work elucidated the size-dependent solidification pathways and microstructural evolution in gas-atomized nickel-based superalloy powders, providing a theoretical foundation for the tailored design and microstructural control of nickel-based superalloy powders for high-performance additive manufacturing applications.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121658"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217095","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Deep learning-based analysis of aluminum particle trajectory and spatial size-velocity correlation in solid propellant combustion at 6 MPa 基于深度学习的6 MPa固体推进剂燃烧铝颗粒轨迹及空间尺寸-速度相关性分析
IF 4.6 2区 工程技术
Powder Technology Pub Date : 2025-09-26 DOI: 10.1016/j.powtec.2025.121646
Zhenghui Yang , Zhibin Sun , Wenjian Cai , Yu Wang , Qianyun Chang , Ziqi Wen , Yang Zhang , YingChun Wu , Xuecheng Wu
{"title":"Deep learning-based analysis of aluminum particle trajectory and spatial size-velocity correlation in solid propellant combustion at 6 MPa","authors":"Zhenghui Yang ,&nbsp;Zhibin Sun ,&nbsp;Wenjian Cai ,&nbsp;Yu Wang ,&nbsp;Qianyun Chang ,&nbsp;Ziqi Wen ,&nbsp;Yang Zhang ,&nbsp;YingChun Wu ,&nbsp;Xuecheng Wu","doi":"10.1016/j.powtec.2025.121646","DOIUrl":"10.1016/j.powtec.2025.121646","url":null,"abstract":"<div><div>Characterizing particle size, position, and velocity, particularly under elevated pressure, is crucial for understanding the underlying combustion dynamics and optimizing propellant formulations to enhance rocket propulsion efficiency. This study presents a deep learning-based data analysis method designed for the detection, tracking, and diameter uncertainty assessment of blurred combustion aluminum particles captured by microscopic imaging. The methodology employs a fine-tuned You Only Look Once model, enhanced by Slicing Aided Hyper Inference, to accurately detect aluminum particles, especially smaller ones. Weighted Distance Intersection over Union is proposed for robust tracking in scenarios with high particle concentrations. Innovatively, a Gaussian kernel-based blur estimation technique is introduced to quantify the uncertainty in particle size measurements. Qualitative and quantitative evaluation experiments have demonstrated the effectiveness of this method. Furthermore, time-resolved individual particle dynamics and spatial particle size and velocity profiles were thoroughly explored using frames captured from a single propellant strand burning test at 6 MPa. Two coupled physical mechanisms underlying particle size dynamics were discovered, while the multimodal behavior of combustion aluminum particles was further analyzed in depth. This research successfully expands the applicability of microscopic imaging, presenting an approach to studying combustion mechanisms under high-pressure conditions.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"468 ","pages":"Article 121646"},"PeriodicalIF":4.6,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145217207","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
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