Numerical Modeling and Optimization of Electrode Induction Melting for Inert Gas Atomization (EIGA)

Electrode Induction Melting Inert Gas Atomization (EIGA) is the state-of-the-art process for the high-quality spherical powder production for additive manufacturing needs. The growing demand for EIGA powders drives the interest for the scale-up of well-established atomization of small Ø50 mm Ti-6Al-4V electrodes, as well as atomization of new refractory materials like Tantalum. However, during first tests with Ø150 mm Ti-6Al-4V and Ø50 mm Tantalum electrodes, the difficulties with melting stability were observed. In order to overcome these difficulties and to improve understanding of details of inductive coupling and favorable melting conditions, a numerical model for the electrode induction melting has been developed and applied.