Atomisering med inert gas i vakuum

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In the world of advanced manufacturing, the quest for perfection in materials has led to the development of numerous sophisticated techniques. One such revolutionary method is Atomisering med inert gas i vakuum (VIGA). This process plays a critical role in producing high-quality metal powders, essential for various applications such as additive manufacturing, powder metallurgy, and specialized coatings. In this article, we delve into the intricacies of VIGA, exploring its processes, benefits, limitations, and applications.

Overview of Vacuum Inert Gas Atomisation

Vacuum Inert Gas Atomisation (VIGA) is a state-of-the-art method used to produce fine, spherical metal powders. This process involves melting a metal under a vacuum and then introducing an inert gas to atomize the molten metal into tiny droplets, which solidify into fine powders. VIGA is renowned for its ability to produce high-purity powders with controlled particle sizes, making it indispensable in high-precision industries.

vacuum inert gas atomisation

Hur Atomisering med inert gas i vakuum Verk

VIGA operates under a controlled environment to ensure the production of superior quality metal powders. Here’s a step-by-step breakdown of the process:

  1. Smältande: Metal or alloy is melted in a vacuum induction furnace.
  2. Atomisering: The molten metal is poured through a nozzle into a chamber where it is atomized by a high-pressure stream of inert gas (such as argon or nitrogen).
  3. Solidifiering: The tiny metal droplets rapidly cool and solidify into fine, spherical powders.
  4. Samling: The powders are collected in a chamber, separated from the inert gas, and sieved to achieve the desired particle size distribution.

Key Metal Powder Models Produced by VIGA

The VIGA process can produce a wide range of metal powders, each with unique properties tailored for specific applications. Here are some notable models:

MetallpulvermodellSammansättningFastigheterTillämpningar
316L rostfritt stålFe-16.5Cr-10Ni-2MoHög korrosionsbeständighet, god svetsbarhetMedicinska implantat, komponenter för flyg- och rymdindustrin
Ti-6Al-4VTi-6Al-4VHögt förhållande mellan styrka och vikt, biokompatibelAerospace parts, biomedical devices
AlSi10MgAl-10Si-0.4MgLåg vikt, god värmeledningsförmågaBildelar, värmeväxlare
Inconel 718Ni-52Cr-19Fe-5Nb-3Mo-1TiHög temperaturbeständighet, korrosionsbeständighetTurbine blades, nuclear reactors
KopparRen CuUtmärkt elektrisk och termisk ledningsförmågaElektriska komponenter, kylflänsar
Maråldrat stål (18Ni300)Fe-18Ni-9Co-5Mo-1.5TiHög hållfasthet, god seghetTooling, high-performance parts
Kobolt-krom (CoCrMo)Co-28Cr-6MoHög slitstyrka, biokompatibelTandimplantat, ortopedisk utrustning
Nickel-Based Superalloys (Hastelloy X)Ni-22Cr-18Fe-9MoExceptional oxidation and corrosion resistanceAerospace, chemical processing
Aluminiumlegering 7075Al-5.6Zn-2.5Mg-1.6CuHigh strength, good fatigue resistanceAerospace frames, sporting goods
Stellit 21Co-28Cr-4MoWear resistance, high temperature stabilityCutting tools, engine components

Applications of Vacuum Inert Gas Atomisation

The versatility of VIGA-produced powders opens up numerous applications across various industries. Here are some of the most significant uses:

IndustriTillämpningar
Flyg- och rymdindustrinTurbine blades, structural components, fasteners
MedicinskOrtopediska implantat, tandproteser
FordonEngine parts, lightweight structural components
ElektronikConductive inks, soldering materials
EnergiNuclear reactors, fuel cells
VerktygSkärande verktyg, formar, matriser
Additiv tillverkning3D-utskrift, prototyptillverkning
YtbeläggningarThermal barrier coatings, wear-resistant coatings

Fördelar med Atomisering med inert gas i vakuum

VIGA offers several advantages that make it a preferred choice for metal powder production:

  • Hög renhet: The vacuum environment minimizes contamination, ensuring high-purity powders.
  • Kontrollerad partikelstorlek: Precise control over atomization parameters results in uniform particle sizes.
  • Spherical Particles: The process produces spherical powders, enhancing flowability and packing density.
  • Mångsidighet: Kan bearbeta ett brett spektrum av metaller och legeringar.
  • Reduced Oxidation: The inert gas environment reduces oxidation, preserving the powder’s properties.

Disadvantages of Vacuum Inert Gas Atomisation

Despite its many benefits, VIGA has some limitations:

  • Hög kostnad: The equipment and operation costs are relatively high compared to other atomization methods.
  • Komplexitet: The process requires sophisticated control systems and skilled operators.
  • Limited Production Scale: Typically, VIGA is more suited for small to medium-scale production.

Comparison of VIGA with Other Atomisation Methods

When choosing an atomization method, it’s crucial to compare VIGA with other techniques like Water Atomisation and Gas Atomisation. Here’s how they stack up:

MetodPartikelformRenhetKostnadProduction ScaleTillämpningar
VIGASfäriskHögHögMediumHigh-precision industries, aerospace
Atomisering av vattenOregelbundenMåttligLågHögPowder metallurgy, steel powders
Gas AtomisationSfäriskHögMåttligMediumAdditive manufacturing, special alloys
vacuum inert gas atomisation

Specifikationer, storlekar och standarder

To ensure consistency and quality, metal powders produced via VIGA adhere to specific standards and specifications:

MetallpulverPartikelstorleksintervall (µm)Standarder
316L rostfritt stål15-45, 45-150ASTM A276, ISO 5832-1
Ti-6Al-4V15-53, 53-150ASTM F2924, ISO 5832-3
AlSi10Mg20-63, 63-125ASTM B928, ISO 209-1
Inconel 71815-45, 45-150ASTM B637, ISO 6208
Koppar10-75, 75-150ASTM B216, ISO 3497
Maråldrat stål (18Ni300)15-45, 45-150ASTM A646, ISO 4955
Kobolt-krom (CoCrMo)20-53, 53-150ASTM F1537, ISO 5832-4
Nickel-Based Superalloys (Hastelloy X)15-53, 53-150ASTM B435, ISO 6208
Aluminiumlegering 707520-63, 63-125ASTM B209, ISO 6362-2
Stellit 2120-63, 63-150ASTM F75, ISO 5832-4

Leverantörer och prisuppgifter

Finding reliable suppliers and understanding pricing details is essential for procurement. Here’s a snapshot of some prominent suppliers and their pricing:

LeverantörErbjudande om metallpulverPrisintervall (per kg)Plats
Sandvik OspreyRostfritt stål, titan$150 – $300Sverige
SnickeriteknikNickel Alloys, Cobalt Alloys$200 – $500USA
Höganäs ABSteel Powders, Aluminum$50 – $200Sverige
LPW-teknikVarious Alloys, Custom Powders$100 – $400STORBRITANNIEN
AP&C (GE Additive)Titan, aluminium$200 – $600Kanada

Jämförelse av för- och nackdelar

Understanding the advantages and limitations of VIGA is crucial for making informed decisions:

ProffsNackdelar
High purity and controlled compositionHigh cost of equipment and operation
Spherical particles with good flowabilityKräver kvalificerade operatörer
Versatility in metal and alloy typesLimited to small to medium-scale production
Reduced oxidation due to inert gasComplex process with stringent control
vacuum inert gas atomisation

VANLIGA FRÅGOR

FrågaSvar
What is VIGA used for?VIGA is used to produce high-quality metal powders for applications in aerospace, medical, and additive manufacturing.
How does VIGA differ from gas atomization?VIGA uses a vacuum and inert gas to minimize contamination and oxidation, resulting in higher purity powders.
What metals can be processed using VIGA?A wide range of metals and alloys including stainless steel, titanium, aluminum, and nickel-based superalloys.
What are the particle size ranges achievable with VIGA?Typically, VIGA can produce powders with particle sizes ranging from 10 µm to 150 µm.
Is VIGA cost-effective?While VIGA offers high quality and precision, it is generally more expensive than other atomization methods.

In conclusion, Vacuum Inert Gas Atomisation stands out as a premier technique for producing high-quality metal powders, essential for various high-precision applications. Its ability to produce spherical, high-purity powders with controlled particle sizes makes it indispensable in fields ranging from aerospace to medical implants. While it comes with higher costs and complexity, the benefits often outweigh the drawbacks for applications demanding top-tier material performance. As industries continue to innovate, the role of advanced techniques like VIGA in shaping the future of manufacturing cannot be overstated.

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MET3DP Technology Co, LTD är en ledande leverantör av lösningar för additiv tillverkning med huvudkontor i Qingdao, Kina. Vårt företag är specialiserat på 3D-utskriftsutrustning och högpresterande metallpulver för industriella tillämpningar.

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