Skip to main content

Research Repository

Advanced Search

New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing

Priyadarshi, Abhinav; Bin Shahrani, Shazamin; Choma, Tomasz; Zrodowski, Lukasz; Qin, Ling; Leung, Chu Lun Alex; Clark, Samuel J.; Fezzaa, Kamel; Mi, Jiawei; Lee, Peter D.; Eskin, Dmitry; Tzanakis, Iakovos


Abhinav Priyadarshi

Shazamin Bin Shahrani

Tomasz Choma

Lukasz Zrodowski

Ling Qin

Chu Lun Alex Leung

Samuel J. Clark

Kamel Fezzaa

Peter D. Lee

Dmitry Eskin

Iakovos Tzanakis


Ultrasonic atomization is one of the promising technologies for producing metal powders for additive manufacturing, where precise control of particle size and morphology is essential. In this study, we coupled an ultrasonic transducer with a carbon fiber plate and atomized liquid droplets and films under different vibration amplitudes. Water, glycerol, and pure aluminum melt were used to study the atomization mechanism and the resulting droplet/powder characteristics, respectively. High-speed optical and ultrafast synchrotron X-ray imaging were used to study in situ the ultrasonic atomization dynamics, including pulsation and clustering of cavities inside the liquid layer/films, development of capillary waves, and formation of liquid droplets. For the first time, we observed and captured the occurrence of cavitation during the atomization of resting drops, films and impact droplets. The inertial cavitation events interfered with the capillary waves across the interphase boundary, puncturing and breaking the boundary to produce atomized mist. The in situ observation revealed the intricate dynamics of ultrasonic atomization and underscored the pivotal role of cavitation events throughout the entire atomization process. We also conducted experiments on ultrasonic atomization of liquid aluminum, producing particles of perfectly spherical shape. The particle size tended to decrease with reduced vibration amplitude Our work has demonstrated the important processing strategies on how to tailor the particle size while ensuring consistent particle shape and morphology, which is the key processing capability for producing high quality powders for additive manufacturing applications.


Priyadarshi, A., Bin Shahrani, S., Choma, T., Zrodowski, L., Qin, L., Leung, C. L. A., …Tzanakis, I. (2024). New insights into the mechanism of ultrasonic atomization for the production of metal powders in additive manufacturing. Additive Manufacturing, 83, Article 104033.

Journal Article Type Article
Acceptance Date Feb 8, 2024
Online Publication Date Feb 16, 2024
Publication Date Mar 5, 2024
Deposit Date Jun 26, 2024
Publicly Available Date Jun 27, 2024
Journal Additive Manufacturing
Print ISSN 2214-7810
Electronic ISSN 2214-8604
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 83
Article Number 104033
Keywords Ultrasonic atomization; Metal powder production; Additive manufacturing; Ultrafast Synchrotron X-ray imaging; Cavitation
Public URL


You might also like

Downloadable Citations