Numerical simulation using in the preparation process of micron‐sized silica–aluminium composite powders by high‐energy alloying: Building visualisation and guiding preparation

Silica-aluminium composite powders are important precursors for the preparation of sealant coatings by supersonic flame spraying. Micron-scale silica-aluminium can be prepared using a planetary ball mill, but powder agglomeration often leads to failure. Using relevant modelling software build 3D mill jar, which based on discrete element method, Hertz–Mindlin contact model and after specifying simulation boundary conditions, process was simulated analysed. Visualise influence parameters such as frequency, size diameter milling balls ball-to-powder weight ratio, systematically analyse microscopic morphology condition agglomerated dispersed powders. The results show that motion during is mainly divided into three representative types: ball–ball impact, crushing against jar wall ball–wall impact. energy transfer efficiency system highest when ratio types uniform. SEM images EDS spectra showed aluminium sufficiently crushed, with an average particle below 1 μm. uniformly distributed surface silicon powder, aggregates reduced.