Molten aluminum was evaporated in a cold gas stream of Ar+O
2 mixture in order to investigate both the evaporation rate of the liquid metal and the characteristics of condensed particle in the reactive gas stream. Experiments were carried out under various oxygen partial pressures (
PO2), temperatures and total gas flow rates using a levitation melting apparatus. The relations between the evaporation rate and
PO2 could be classified into three regions;
i.e. low, medium and high
PO2 regions. The rate in each
PO2 region was discussed using a counter flux model of aluminum vapor and oxygen in the boundary layer around the levitated specimen.
The results obtained in each
PO2 region were summarized as follows:
(1) Low
PO2 region: As most oxygen reacted with aluminum particles after condensation of the aluminum vapor, the evaporation rate was almost the same as the one in the Ar gas stream irrespective of
PO2. The condensed particles were a mixture of aluminum and widely defined γ-Al
2O
3. The amount of the γ-Al
2O
3 increased with an increase of
PO2.
(2) Medium
PO2 region: As oxygen diffused beyond the site where the aluminum vapor nucleated, it reacted with the aluminum vapor. The boundary layer thickness for the aluminum vapor decreased with an increase of
PO2, so that the evaporation rate increased linearly. The condensed particles were almost widely defined γ-Al
2O
3. As a whole, it could be said that the mean particle diameter decreased with increasing
PO2 and total gas flow rate and with decreasing temperature.
(3) High
PO2 region: As oxygen diffused onto the levitated specimen surface, an oxide film covered on the specimen surface. Accordingly, the vaporization of aluminum ceased and no particle was obtained.
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