METAL POWDER PRODUTION

INDEX

Powder Production Methods

Atomization

Type of Atomization

Bibliography

POWDER PRODUCTION METHODS

In general, producers of metallic powders are not the same companies as those

that make PM parts.

Any metal can be made into powder form.

Three principal methods by which metallic powders are commercially

produced1. Atomization2. Chemical3. Electrolytic

In addition, mechanical methods are occasionally used to reduce powder sizes

balls used in ball-point

pens

gears, cams

cutting tools (inserts)

porous metal filters

oil-impregnated bearings

piston rings in engines

ATOMIZATIONProduces a liquid-

metal stream by

injecting molten

metal through a

small orifice

The stream is

broken up by jets of

inert gas or air

water

The size and shape of the particles from atomization depend on the temperature, flow rate, size of nozzle, and the jet characteristics

When water is used it creates a slurry metal powder and leaves a liquid at the bottom of the atomization chamber

The water cools the metal faster for a higher production rates

Methods of metal-powder production by atomization: (a) gas atomization; (b) water atomization; (c) centrifugal atomization with a spinning disk or cup; and (d) atomization with a rotating consumable electrode

CENTRIFUGAL ATOMIZATION

The process in which the molten-metal

drops onto a rapidly rotating disk or cup.

The centrifugal forces break up the

molten-metal stream to generate particles

Another method is that a consumable

electrode is rotating rapidly in a helium

filled chamber

Fe powders made by water atomization

Ni-based super alloy made by the rotating electrode process

HYBRID ATOMIZATION

Composition Percentage

Aluminum 95.97

Copper 0.26

Iron 2.77

Zinc 0.04

Silicon dioxide -

Insoluble matter -

COMPOSITION OF RAW ALUMINUM METAL

S P E C I F I C AT I O N O F M E LT I N G U N I T

DESIGN STRUCTURE OF HYBRID ATOMIZATION

Gas supply system

Flexible wire

Powder collector

Nitrogen gas

motor

Furnace

Aluminum metal

Melting (~1000ºC)

Nitrogen

Aluminum Powder (<75µm)

Powder Collecting

Centrifugal Atomizing

Gas Atomizing

Sizing

Figure: Flow Diagram of Powder Production Procedure

UPPER PART: The melting unit

MIDDLE PART: Atomizer, Disk and Gas supply

LOWER PART: High speed motor, Air cleaner and powder collector

This Design can be studied in three different parts:

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