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<p>Realizing particle size control during the plasma rotating electrode process (PREP) is critical for producing high-quality Ta-10W alloy powder and the resulting additive manufacturing (AM) components. This study employed computational fluid dynamics (CFD) to numerically simulate the PREP of the Ta-10W alloy. The influences of key operating parameters including rotating speed and melting rate on the particle size of the Ta-10W alloy powder were systematically analyzed, and the underlying mechanisms governing atomization behavior were elucidated. The results demonstrate that the influence of rotating speed and melting rate on the PREP is complex. To obtain fine refractory Ta-10W alloy powder, a reasonable match between the rotating speed and melting rate is essential. Deviations (low melting rate/high rotating speed or vice versa) generate coarse particles. This work enhances the understanding of the PREP for Ta-10W alloy and provides valuable guidance for producing high-performance powders with an improved fine powder yield.</p>

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Effects of Plasma Rotating Electrode Process Parameters on the Particle Size of Ta-10W Alloy Powder

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • Dengzhi Yao,
  • Shaoyang Zhao,
  • Ming Wei,
  • Guangyu Yang,
  • Bang Xiao,
  • Jian Wang

摘要

Realizing particle size control during the plasma rotating electrode process (PREP) is critical for producing high-quality Ta-10W alloy powder and the resulting additive manufacturing (AM) components. This study employed computational fluid dynamics (CFD) to numerically simulate the PREP of the Ta-10W alloy. The influences of key operating parameters including rotating speed and melting rate on the particle size of the Ta-10W alloy powder were systematically analyzed, and the underlying mechanisms governing atomization behavior were elucidated. The results demonstrate that the influence of rotating speed and melting rate on the PREP is complex. To obtain fine refractory Ta-10W alloy powder, a reasonable match between the rotating speed and melting rate is essential. Deviations (low melting rate/high rotating speed or vice versa) generate coarse particles. This work enhances the understanding of the PREP for Ta-10W alloy and provides valuable guidance for producing high-performance powders with an improved fine powder yield.