Free-Fall Nozzle

Aerosol Generation

Mechanical separation of the atomizing gas from the molten metal stream is a key feature of this design. Because the gas jets do not interact with the metal inside the nozzle itself, the risk of nozzle freezing or blockages is significantly reduced. This separation allows for longer continuous run times and more consistent powder production.

The distance the molten metal falls before it meets the gas stream must be carefully controlled to ensure optimal fragmentation of the liquid.

Powder Quality

Particle size and shape are determined by the interaction between the free falling metal stream and the high velocity gas. The atomization process occurs in a specific region below the nozzle where the gas jets converge. This configuration allows for the production of highly spherical particles with fewer satellite particles, which is ideal for powder bed fusion processes.

The resulting powder has excellent flowability and high packing density, which are critical for producing high strength components.

Process Control

Operational parameters such as melt temperature, gas pressure, and nozzle diameter must be optimized to achieve the desired powder characteristics. The free-fall nozzle configuration is particularly suited for processing reactive or high melting point alloys, as the lack of close contact between the gas and the nozzle minimizes thermal shocks. Powder production facilities use this technology to supply consistent materials to the aerospace, medical, and tooling industries.

The reliability of this process ensures a steady supply of high performance powders for critical manufacturing applications.