Intelligent Sensors for Atomization Processing of Molten Metals and Alloys

This paper briefly introduces the principles of atomization processing of molten metals and alloys. It is shown that particle size and velocity are considered the two most important variables to monitor and control the atomization process. Potentially applicable instrumentation are discussed, and opportunities for developing intelligent sensors for monitoring and control of the process are proposed. Several on-line sensors suitable for atomization of molten metals and alloys are compared, including the laser diffraction particle analyzer (LDPA), particle counting, sizing and velocity measurement (PCSV) instruments, the phase/Doppler particle analyzer (P/DPA), the electric principle based monitor for particulates (EPMP), various imaging techniques for particle sizing (ITPS), and infrared image analysis (IIA) instruments. The isokinetic probe is introduced as a direct method to sample powders at the desired point in the atomized spray. Prospects and problems of integrating instruments ba..