The Paton Welding Journal, 2025, №10

2025 №10 (06)

DOI of Article 10.37434/tpwj2025.10.01

2025 №10 (02)

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The Paton Welding Journal, 2025, #10, 3-11 pages

Prospects of ultrasound application in the production of dispersed granules by gas and plasma-arc atomization of metal melts and compact materials (Review)

V.M. Korzhyk, O.S. Tereshchenko, D.V. Strohonov, O.I. Demianov, O.V. Ganushchak

E.O. Paton Electric Welding Institute of the NASU. 11 Kazymyr Malevych Str., 03150, Kyiv, Ukraine. E-mail: vnkorzhykn@gmail.com

Abstract
The technological features of ultrasonic vibrations utilizing for the atomization of microvolumes of metal melts in production technologies of dispersed spherical powders are considered, such as: gas atomization, ultrasonic atomization on sonotrode, plasma arc atomization by means of ultrasonic standing wave, electric arc atomization with the application of ultrasound to the wire, and plasma arc atomization with the application of ultrasonic vibrations to the atomized material. The influence of ultrasonic vibrations on the process of melt droplet formation and detachment for the aforementioned methods is analyzed. It is established that the superposition of ultrasound promotes a refinement of the initial melt droplets, intensifies dispersion due to putting additional pressure on the melt droplets, and, as a result, contributes to the narrowing of the particle size distribution. It has been found that among the analyzed approaches for obtaining spherical powders using high-frequency acoustic vibrations, the most promising is the technology of plasma arc atomization of wires and rods under the condition of applying ultrasound directly to the billets. An analysis of the efficiency and prospects of using plasma-arc atomization technologies with the introduction of ultrasonic vibrations into the atomized billets has been conducted, and it is hypothesized that this approach will allow increasing the yield of ‒63 μm fraction powders up to 80‒90 %, which is promising for application in the production of powders for additive manufacturing technologies. alloys with variable thicknesses ranging from 45 to 65 mm while maintaining the same number of passes.
Keywords: ultrasonic atomization, dispersion, plasma arc atomization, gas atomization, spherical powders, particle size distribution

Received: 23.04.2025
Received in revised form: 22.07.2025
Accepted: 25.10.2025

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Suggested Citation

V.M. Korzhyk, O.S. Tereshchenko, D.V. Strohonov, O.I. Demianov, O.V. Ganushchak (2025) Prospects of ultrasound application in the production of dispersed granules by gas and plasma-arc atomization of metal melts and compact materials (Review). The Paton Welding J., 10, 3-11.

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