System för metallförstoftning

Innehållsförteckning

Metal atomization is a manufacturing process where metal is turned into powder form by breaking up molten metal into tiny droplets. This powder can then be used to manufacture parts through methods like metal injection molding, hot isostatic pressing, additive manufacturing, and more. System för metallatomisering are the equipment used to carry out this process.

Översikt över system för metallförstoftning

Metal atomization systems consist of mechanisms to melt metal stock, deliver the molten metal to an atomization area, break up the metal into fine droplets, and collect the solidified powder. Key components include furnaces, tundishes, delivery mechanisms, atomizers, cooling chambers, cyclone separators, bag filters, and powder collection systems.

There are two main types of atomization systems:

  • Gas atomization – uses high pressure gas to break up the molten metal stream
  • Water atomization – uses high pressure water to break up the molten metal

Gas atomization produces finer powders on average while water atomization offers higher production rates. Both methods can achieve reasonably high yields depending on the design and operating parameters.

system för atomisering av metall Sammansättning

KomponentBeskrivning
FurnaceMelts metal stock into liquid state through induction, combustion, etc. Common types are induction furnaces, electric arc furnaces.
TundishActs as a reservoir to hold the molten metal after it leaves the furnace. Provides continuous flow of metal to delivery system.
Delivery systemTransfers molten metal from tundish to atomizer. Often uses pouring funnel, heated launder, or pressurized nozzle.
AtomiserareBreaks up molten metal into droplets using gas or water jets. Various designs and number of jets.
Cooling sectionAllows powder to solidify after atomization before collection. Air or inert gas used as cooling media.
Separation systemCaptures fine powder particles while allowing cooling media to be recirculated. Uses cyclones, bag filters.
Powder collectionCollects atomized powder for retrieval. Often drum or box containers, glove boxes, or conveyor belts leading to containers.
system för atomisering av metall

system för atomisering av metall Typer

There are a few common atomizer designs used in commercial metal powder production:

Gas Atomizers

  • Supersonic Gas Atomizer – Laval nozzles accelerate inert gas up to sonic velocities.
  • Close-Coupled Gas Atomizer – Multiple gas jets impinging on molten metal stream.
  • Free Fall Gas Atomizer – Molten metal stream falls freely through high velocity inert gas.

Water Atomizers

  • Pressure Water Atomizer – High pressure water jets hit molten metal stream.
  • Rotating Water Atomizer – Molten metal stream contacts spinning water jets.
  • Submerged Water Atomizer – Water jets placed under molten metal stream surface.

Metal Atomizer Attributes

AttributBeskrivning
Typ av gasInert gases like nitrogen, argon used to prevent oxidation. Nitrogen most economical.
Water pressure30-150 MPa pressure needed to properly atomize metals.
Number of jetsMore jets increases metal breakup but can reduce yield. Around 4-8 common.
Jet arrangementRound or rectangular jet patterns covering metal stream. Rectangular more uniform powder.
Jet velocityFaster inert gas velocities make finer powders. Optimal gas speed varies for each metal.
FallhöjdHeight molten metal stream falls before hitting jets. Affects particle size distribution.
Flow designSmooth, laminar metal flow preferred to prevent splashing into droplets early.
Nozzle designPrecisely machined nozzles in gas atomizers are crucial for performance.
Cooling rateFaster cooling makes finer powders. Depends on gas/water temperature and chamber.
Separation efficiencyHigher separation rates increase yield. Self-inerting cyclones work well.
Collection methodClosed systems prevent powder oxidation. Automated drum conveyors common.

Metal Powder Characteristics

The properties of metal powder produced depends heavily on the atomization process parameters and conditions.

Pulver Egenskaper

AttributTypiskt intervall
Partikelns formIrregular, spherical, satellite structures
Partikelstorlek1 micron to 1000 micron
Fördelning av partikelstorlekGaussian, log-normal common
Skenbar densitetGenerally 30-80% of true density
TappdensitetAround 60-95% of true density
FlödeshastighetVaries greatly with shape, size distribution
Renhet93-99.5% target range
Syrehalt300-3000 ppm range
Kväveinnehåll75-1500 ppm range

Effect on Part Properties

Powder AttributeEffect on Sintered/Printed Parts
PartikelstorlekFiner powders increase density, reduce pores
StorleksfördelningWider distribution gives better packing density
Partikelns formSpherical particles have better flow and packing
Skenbar densitetHigher density increases green strength for handling
TappdensitetHigher density gives fewer shrinkage voids after sintering
RenhetHigher purity reduces defects like inclusions
SyrehaltAbove 3000 ppm can cause porosity issues

metal atomization systems Applications

The fine metallic powders made via atomization are used across many industries to manufacture high performance parts.

IndustriExempel på tillämpningar
FordonEngine components, gears, fasteners
Flyg- och rymdindustrinTurbine blades, airfoil components
BiomedicinskOrtopediska implantat, kirurgiska verktyg
ElektronikShielding, connectors, contacts
EnergiNuclear & turbine parts subjected to extreme environments
Additiv tillverkning3D printed final parts across all industries

Popular metal atomization systems Used

Many alloys are atomized into powder form for part manufacturing. Here are some common metals and alloys atomized:

MaterialViktiga egenskaper
TitanlegeringarHigh strength, low weight ratio. Biocompatibility.
NickellegeringarRetains properties at high temperatures. Corrosion resistance.
KoboltlegeringarBiocompatibility. Wear resistance properties.
VerktygsstålHigh hardness levels after heat treatment.
Rostfria stålUtmärkt korrosionsbeständighet.
AluminiumlegeringarLight weight. Good thermal conductivity.
KopparlegeringarHigh thermal & electrical conductivity.
Magnetic alloysHigh permeabilities for magnetic applications.

Metal Powder Suppliers & Pricing

There are a number of reputable suppliers that manufacture & distribute metal powders worldwide. Prices depend on alloy, particle size range, and quantity ordered.

LeverantörPrice Ranges
AP&C$50 – $1500 per kg
Sandvik Osprey$100 – $2000 per kg
Carpenter Pulverprodukter$75 – $1800 per kg
Praxair Ytteknologi$250 – $2500 per kg
Höganäs$45 – $1600 per kg
ECKA Granulat$80 – $1200 per kg

Higher performing alloys or finer control over powder size distribution demands higher prices, while more common metals and alloys are more economical at production volumes.

Metal Atomization vs Other Methods

MetodFördelarBegränsningar
Metal atomization– Finer powders
– Higher purity
– Range of alloys
– High capital costs
– Requires significant processing expertise
Elektrolytisk process– Very fine & clean powders– Limited to conductive alloys
– Expensive
Mechanical attrition– Simple & inexpensive
– Wide range of metals
– Lower achievable fineness
– Higher oxidation
Chemical precipitation– Pure elemental & alloyed powders– Powder agglomeration issues
– Potential contamination
Termisk sprutning– Can produce spherical powder– Oxide inclusions- Broad size distributions

Atomization offers reasonably fine and clean powders across a wide range of alloys at good production volumes. Safety precautions are necessary when handling fine metallic powders.

Key Considerations for Selection

Important factors guiding metal atomization system selection include:

FaktorBeskrivning
Production rateRequired powder output in kg/hr. Defines capacity.
Target particle sizeNeeds defined fineness, distribution. Impacts yield, cost.
Legeringens sammansättningMost systems handle a range of alloys. May influence choice of melting method, atomizer, gas/water pressures.
Product qualityPurity levels, oxygen pickup limits, size consistency requirements dictate parameters.
Handling considerationsClosed powder handling preferred. Some metals pose health risks.
Powder end usePart property requirements – density/porosity, fluidity, shape factors.
Operating costsUtility inputs for melting, gases, water. Labor, maintenance expenses.
SäkerhetPressure vessels for liquids/gases require specific regulation compliance.
Environmental impactGas emissions, water use/disposal considerations apply.

Careful determination of throughput requirements, quality metrics, operating conditions, safety parameters, and costs based on end part requirements is necessary.

system för atomisering av metall Underhåll

Proper maintenance is required to keep atomization equipment performing optimally.

KomponentMaintenance ActivitiesFrekvens
FurnaceInspect refractory & heating elements. Replace as needed.6-12 months
MunstyckenInspect nozzle jet openings for wear/clogs.Monthly
Water filters & linesFlush lines & replace filters regularly.2-4 veckor
Gas lines & valvesCheck for leaks, blockages. Confirm pressures.2-4 veckor
SeparatorsInspect filter medium condition & seals.4-6 months
Controls & sensorsCheck calibration. Test interlocks & responses.6-12 months
Powder collectorInspect container condition & seals. Confirm inert gas levels for closed systems.Monthly
System interiorsClean built-up metal dusts throughout. More frequent closer to metal stream paths.Monthly

Detailed equipment monitoring, preventive & predictive maintenance minimizes unexpected interruptions in production.

system för atomisering av metall

Vanliga frågor

Q: What is an appropriate level of automation & control for metal atomization systems?

A: A high degree of automation in material feed, process monitoring and control is recommended for consistent powder production and safety. Key process variables like temperatures, pressures, gas flows should have automatic feedback control. System oversight, parameter tuning and manual operation mode is still prudent.

Q: How to determine if gas atomization or water atomization is preferred for an application?

A: Water atomization offers much higher metal throughput rates compared to gas atomization. But gas atomization can achieve finer average powder sizes suitable for microstructured parts. For typical MIM powders above 15 microns, water atomization is preferred for economy.

Q: What safety measures are recommended for operating atomization systems?

A: Proper personnel protective equipment for handling high pressure systems and fine powders is mandatory. Water atomization systems should have splash guards. Closed powder handling with inert gas glove boxes, automated powder collectors improves safety. Lockouts, access restrictions, emergency stops critical.

Q: What causes common powder production problems in atomization?

A: Irregular powder sizes & satellite particles often stem from uncontrolled metal stream flows. Contamination can result from nozzle wear, degraded filter media or leaks. Chamber & separator fouling from overflows reduces yield over time. Monitoring & optimizing flow parameters is key.

Q: What expertise is required to effectively operate atomization systems?

A: While controls automation reduces manual burden, trained metallurgical or materials science engineers familiar with powder production are ideal to oversee equipment. Mechanical & electrical engineers needed for maintenance & troubleshooting. Operators should receive proper metal powder handling training.

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