Atomization simulation and preparation of 24CrNiMoY alloy steel powder using VIGA technology at high gas pressure

To more accurately analyze the atomization process of vacuum induction melting gas atomization (VIGA) technology at high gas pressure, a new method was proposed based on the combination of VOF and DPM theories. Numerical simulations and powder preparation tests were used to verify the applicability of this method. The results indicated that the large eddy simulation model could accurately visualize the large droplet separation process from the liquid column in the primary atomization. Additionally, the TAB model was used to predict the particle size distribution in the secondary atomization. The simulated results were consistent with the powder preparation test. 24CrNiMoY alloy steel powder prepared at 9.0 MPa had the highest flowability and apparent density. The powder is suitable for selective laser melting technology. This research is of guiding significance and serves as a methodological reference for understanding the atomization process of VIGA technology.