What Is The Function of Ultrasonic Metal Spray Atomization?

In ultrasonic metal spraying technology, atomization is one of the core links, which directly affects the quality, performance and spraying efficiency of the coating. Its main functions can be analyzed in detail from the following aspects:

1. Converting Metal Materials into Fine, Uniform Droplets

The principle of ultrasonic metal spraying is to use ultrasonic vibrations (typically with a frequency above 15kHz) to break molten or semi-molten metal materials (such as wire, powder, or molten metal) into tiny droplets.

   ●Key Function: Atomization disperses the originally continuous metal material into droplets with diameters typically in the micrometer range (1-100μm). These droplets are transported to the substrate surface under the influence of airflow or centrifugal force.

   ●Importance: The fineness of the droplets directly determines the density and uniformity of the coating. If the droplets are too large, the coating is prone to porosity, particle agglomeration, and uneven thickness. On the other hand, uniform, fine droplets produce a smooth, dense coating.

2. Ensure Coating Uniformity and Consistency

During the atomization process, the high-frequency energy of ultrasonic vibrations evenly distributes force on the metal material during fragmentation, resulting in a cluster of droplets     with a narrow size distribution.

  ●Specific Performance:

      ○ Uniform droplet size prevents surface roughness or localized accumulation of large particles;

      ○ Droplets are evenly dispersed in the airflow, resulting in consistent coverage density when sprayed onto the substrate, minimizing coating thickness variation;

      ○ Small droplets are more easily penetrated and adhered to complex substrates (such as grooves and curved surfaces), ensuring coating integrity.

3. Improving Droplet Kinetic Energy and Adhesion

The droplets produced by ultrasonic atomization are not only small but also possess a certain amount of kinetic energy (derived from the ultrasonic vibration and the propulsion of the auxiliary airflow).

  ●Mechanism of Action: When the droplets impact the substrate surface, appropriate kinetic energy causes the droplets to undergo plastic deformation ("flattening"), forming a tight bond with the substrate or underlying coating, reducing interfacial porosity.

  ●Comparative Advantages: Compared to traditional arc spraying or flame spraying, the kinetic energy of droplets produced by ultrasonic atomization is easier to control, enabling good adhesion at lower temperatures, reducing the risk of substrate deformation or performance degradation caused by high temperatures.