Physical models for vacuum-induced multistage atomization of high-entropy FeCoCrNiMo alloy powder for 3D printing

The atomization process of high-entropy FeCoCrNiMo alloy was tested using electrode induction gas atomization (EIGA) at different powers, pressures and rotary speeds. The modelization about the physical essence in the metal drop atomization was studied. A surface tension model, a specific surface energy model, a cooling rate model, and a solidification kinetic model of the alloy drop atomization process were built. Based on these models, the quantitative relationships between the powder particle size and process parameters during the alloy atomization were determined. Together with the results of particle size and scanning electron microscopy-based morphology of the powder obtained from EIGA under different process systems, the accuracy of the above physical models was validated.