airatomizing

Air atomizing, or air-atomized spraying, is a liquid atomization process that uses compressed air to break a liquid into fine droplets as it exits a nozzle. In an air atomizing nozzle, liquid under pressure is introduced with a stream of compressed air that shears the liquid into a spray; the air entrains and disperses the liquid, producing droplets whose size and spray pattern can be adjusted by varying liquid pressure, air pressure, and nozzle geometry. There are two main configurations: internal-mix nozzles, where air and liquid mix inside the nozzle before exiting, and external-mix (air-cap) nozzles, where air and liquid mix outside the nozzle at the outlet. The spray patterns commonly produced include full-cone, hollow-cone, and flat-fan forms, with droplet sizes ranging from coarse to fine depending on operating conditions.

Air atomizing systems are used in a variety of industries, including industrial coating and painting (such as automotive and aerospace finishes), applying adhesives and sealants, humidification and cooling in process environments, and agricultural spraying. They are valued for producing fine, uniform droplets and for enabling adjustable spray characteristics over a wide range of viscosities and surface tensions. Advantages include effective atomization at relatively low liquid viscosity, improved transfer efficiency, and the ability to control spray pattern and droplet size through air pressure and liquid pressure. Disadvantages include higher energy consumption due to compressed air, sensitivity to air quality and liquid properties, potential overspray, and more maintenance to prevent clogging and wear. In practice, air atomizing is chosen when a high-quality finish or precise application is required; when energy use or solvent loss is a concern, alternatives such as hydraulic-atomizing or airless spraying may be considered.