CN110421178B - Equipment and method for preparing high-quality spherical welding powder - Google Patents
Equipment and method for preparing high-quality spherical welding powder Download PDFInfo
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- CN110421178B CN110421178B CN201910850071.3A CN201910850071A CN110421178B CN 110421178 B CN110421178 B CN 110421178B CN 201910850071 A CN201910850071 A CN 201910850071A CN 110421178 B CN110421178 B CN 110421178B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F9/10—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying using centrifugal force
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Abstract
The equipment comprises a bucket-shaped atomizing tank (1), a feeding device arranged on one side of the top of the atomizing tank, a rotary ultrasonic atomizing device (2) arranged at the center of the top of the atomizing tank, a cooling airflow disc (8) arranged in the atomizing tank and positioned at the lower part of the ultrasonic atomizing device, an infrared radiation heater (21) and a fluidized separation airflow disc (20) which are positioned below the cooling airflow disc, an atomizing area cooling device and a fluidized separation device which are arranged outside the atomizing tank, and an ultrasonic screening machine (24) or a turnover tank (25) which is arranged at the bottom of the atomizing tank. The method has the advantages of high atomization efficiency and control precision, simple operation, good sphericity of the prepared spherical welding powder, smooth and defect-free powder surface, and crystal structure meeting the higher quality requirement of the solder paste.
Description
Technical Field
The invention relates to the technical field of welding powder production equipment and a production method.
Background
The solder material is an indispensable connecting material in the electronic industry, and the application of the surface mount technology (STM) which takes solder paste as a main connecting material enables the electronic assembly process to be efficient and miniaturized, and the SMT technology becomes the mainstream of the electronic assembly technology. The soldering paste mainly comprises soldering powder and soldering paste, wherein the weight ratio of the soldering powder accounts for about 88-90%, and the soldering powder is one of the most main materials for preparing the soldering paste.
The prior method for producing spherical welding powder comprises airflow atomization, centrifugal atomization and ultrasonic atomization, the sphericity of the welding powder produced by the gas atomization is poor, satellite balls are more, the sphericity of the centrifugally atomized tin powder is not easy to control, and the sphericity of the ultrasonically atomized tin powder is better. Because the ultrasonic atomization device is designed in the atomization cavity, a sealed ultrasonic transducer cooling part needs to be designed independently, and the installation and the maintenance are complex. In addition, the cooling speed of alloy liquid drops needs to be controlled in an atomization area, common atomization equipment adopts an atomization cavity jacket water cooling design, the temperature of the atomization area is indirectly controlled, and the problems of low and unbalanced control precision, large temperature gradient and the like exist. In addition, in the spheroidizing process of the alloy liquid drop, the low-oxygen atmosphere of an atomizing area needs to be controlled to adjust and control the surface tension of the liquid drop to realize the sphericity of the powder, generally, an atomizing cavity is firstly vacuumized, nitrogen or other inert gases are injected, and then air is supplemented to realize the low-oxygen atomizing atmosphere, so that the problems of large gradient and non-uniformity of oxygen concentration exist. In addition, the atomized powder has certain micro powder (less than 5um), and the atomized powder is difficult to sieve and remove by adopting a common ultrasonic sieving machine and needs to be classified by adopting complex airflow.
Disclosure of Invention
The invention aims to solve the problems in the prior art and provides equipment for producing high-quality spherical welding powder by adopting a rotary disc type ultrasonic atomization process and a preparation method thereof, which have high atomization efficiency and control precision and are simple to operate, so as to prepare the spherical welding powder with good sphericity, smooth and defect-free powder surface and crystal structure meeting the higher quality requirement of solder paste.
The purpose of the invention is realized by the following technical scheme:
an apparatus for preparing high-quality spherical welding powder comprises a bucket-shaped atomizing tank, a feeding device arranged on one side of the top of the atomizing tank, a rotary ultrasonic atomizing device arranged at the center of the top of the atomizing tank, a cooling airflow disc arranged in the atomizing tank and positioned at the lower part of the ultrasonic atomizing device, an infrared radiation heater and a fluidized separation airflow disc which are positioned below the cooling airflow disc, an atomizing area cooling device and a fluidized separation device which are arranged outside the atomizing tank, and an ultrasonic screening machine or a turnover tank arranged at the bottom of the atomizing tank;
the feeding device comprises a melting material holding furnace and a feeding pipe which is arranged at the bottom of the melting material holding furnace and is introduced into the atomizing tank, the melting material holding furnace is of a double-furnace-liner structure and comprises a melting material liner and a heat preservation liner which are adjacently arranged in a furnace shell, the bottoms of the melting material liner and the heat preservation liner are communicated through a liquid conveying channel, the melting material liner and the heat preservation liner are respectively provided with an independent heating temperature control system, and the feeding pipe is provided with a heating temperature control system;
the cooling device of the atomization area comprises a gas thermostat, an oxygen content analyzer arranged on the thermostat, an oxygen cylinder and an oxygen inlet electromagnetic valve which are connected with the gas thermostat, a nitrogen cylinder and a nitrogen inlet electromagnetic valve which are connected with the gas thermostat, and the cooling device of the atomization area is connected with the gas thermostat and a cooling airflow disc through a cooling airflow pipe of the atomization area;
the fluidization sorting device comprises a cloth bag dust collector communicated with the upper part of the atomization tank through a micro powder pipe and a circulating fan connected with the cloth bag dust collector, wherein a blowing port of the circulating fan is connected with the fluidization sorting airflow disc through a fluidization sorting airflow pipe;
and a discharge valve and a feeder are sequentially arranged at a discharge port at the bottom end of the atomizing tank, and an outlet of the feeder is connected with a feed port of the ultrasonic screening machine or the turnover tank.
Furthermore, the rotary ultrasonic atomization device comprises a shell, an ultrasonic transducer arranged in the shell, a fixing ring sleeved at the top end of the shell, a mounting frame arranged in the fixing ring, a top cover arranged at the top end of the fixing ring, a conductive slip ring arranged on the top cover, a synchronous belt pulley arranged at the bottom end of the shell and sleeved on a central shaft, and a mounting flange fixedly connected to the bottom of the synchronous belt pulley; the upper end of a central shaft of the ultrasonic transducer is fixedly arranged on the mounting frame, the lower end of the central shaft of the ultrasonic transducer is fixedly connected with a central shaft of the synchronous belt pulley, and the conductive slip ring is connected with the ultrasonic transducer; the lower end of a central shaft of the synchronous belt pulley is fixedly connected with an ultrasonic amplitude transformer, the bottom end of the ultrasonic amplitude transformer is connected with a rotary ultrasonic atomizing disc, and the rotary ultrasonic atomizing disc is horn-shaped with a downward opening; the rotary ultrasonic atomization device is fixed on the top of the atomization tank through a mounting flange, and the driving motor drives the rotary ultrasonic atomization device to rotate through a synchronous belt sleeved on a synchronous belt pulley; the cooling airflow disc is sleeved on the ultrasonic amplitude transformer and positioned above the ultrasonic atomizing disc; the ultrasonic amplitude transformer is positioned in the bucket-shaped atomization tank, and the ultrasonic transducer and the part above the shell are positioned outside the bucket-shaped atomization tank.
Furthermore, a vent hole is arranged on the shell of the rotary ultrasonic atomization device.
Furthermore, the cooling airflow disc comprises a small circular disc body with an annular inner cavity, and downward air outlet pipes which are radially and uniformly distributed on the bottom surface of the disc body, wherein the downward air outlet pipes are communicated with the annular inner cavity.
Furthermore, the fluidized sorting airflow disc comprises a small circular disc body with an outer ring annular inner cavity, and upward air outlet pipes which are radially and uniformly distributed on the top surface of the outer ring of the disc body, wherein the upward air outlet pipes are communicated with the outer ring annular inner cavity.
Still further, the diameter of the fluidized sort flow tray of the present invention is greater than the diameter of the cooling flow tray.
The method for producing the high-quality spherical welding powder by adopting the equipment comprises the following steps:
A. putting the prepared alloy ingot into a melting material liner of a melting material heat preservation furnace, starting the melting material liner and the heat preservation liner for heating, setting respective heating temperature control systems, controlling the temperature parameter to be 50-100 ℃ above the liquidus of the alloy, and after the alloy ingot is melted in the melting material liner, feeding the alloy ingot into the heat preservation liner along a liquid conveying channel at the bottom; continuously adding new materials into the melting container along with the descending of the alloy melting liquid level in the melting container and the ascending of the liquid level in the heat preservation container to ensure that the alloy liquid level meets the process requirements;
B. starting an infrared radiation heater to preheat the ultrasonic rotary ultrasonic atomizing disk, ensuring the fluidity of the alloy melt at the initial atomization on the atomizing disk, starting a feeding pipe and setting a heating temperature control system thereof, controlling the temperature parameter to be 50-100 ℃ above the alloy liquidus, simultaneously starting a driving motor and an ultrasonic vibration power supply of the rotary ultrasonic atomizing device, starting the rotary ultrasonic atomizing device to rotate, spraying the alloy melt in the heat preservation liner to the rotary ultrasonic atomizing disk along the outlet of the blanking pipe to start atomizing, spraying the alloy melt on the static section of the rotary ultrasonic atomizing disk firstly, under the action of the centrifugal force of rotation and the gravity of the molten alloy, the molten alloy flows spirally on the disk surface of the atomizing disk and quickly spreads on the stationary section to form a uniform thin liquid film, then the alloy enters a vibration section of a rotary ultrasonic atomizing disc to form fine atomized alloy liquid drops under the high-frequency ultrasonic of a rotary ultrasonic atomizing device;
C. starting an atomization area cooling device when the alloy melt starts to be atomized, setting an oxygen content control value of an atomization area of an oxygen content analyzer, and controlling an oxygen inlet electromagnetic valve and a nitrogen inlet electromagnetic valve by the oxygen content analyzer according to the set value to uniformly mix oxygen and nitrogen in proportion; meanwhile, setting a control value of a gas thermostat, controlling the temperature of the mixed gas in the gas thermostat to reach the process requirement, allowing the mixed gas to enter an atomization area cooling airflow disc through an atomization area cooling airflow pipe, and directly acting on the just-atomized alloy liquid drops through a downward air outlet pipe, so as to realize accurate control of the cooling speed and the spheroidizing speed of the ultrasonically atomized alloy liquid drops, thereby obtaining spherical welding powder;
D. when the alloy melt starts to be atomized, the fluidization separation device is started, air supplied by the circulating fan enters the fluidization separation airflow disc through the fluidization separation airflow pipe, separation airflow is supplied upwards through the upper air outlet pipe, micro powder is separated out, a gas-solid mixed phase containing the micro powder enters the cloth bag dust collector through the micro powder pipe, and the filtered gas returns to the circulating fan;
E. when the alloy melt starts to atomize, the discharge valve and the feeder are started, and the spherical welding powder falls into the ultrasonic screening machine for screening or directly enters the turnover tank.
The invention has at least the following advantages:
1. according to the invention, the material is fed to the atomizing cavity through the material melting heat preserving furnace and the feeding pipe in the feeding device, and the feeding structure at the bottom of the double furnace liners of the material melting heat preserving furnace can ensure that the temperature of alloy melt in the heat preserving liners is uniform and pure in the material melting process;
2. the rotary disc type ultrasonic atomization is adopted to atomize the solder alloy melt into liquid drops with normal distribution particle size, the horn-shaped rotary ultrasonic atomization disc with a downward opening enlarges the atomization surface of the existing atomization equipment from a smaller conical surface area to the disc surface, so that the atomization area can be increased, the flow of the atomized alloy melt is improved, a uniform thin liquid film can be quickly spread on the disc surface, then fine atomized alloy liquid drops are formed under high-frequency ultrasound, the atomization efficiency and the atomization effect are improved, and the subsequent formation of high-quality spherical welding powder is facilitated;
3. an infrared radiation heater for preheating the rotary ultrasonic atomizing disk is arranged, so that the superheat degree of the alloy melt on the surface of the atomizing disk can be controlled, the fluidity and the surface tension of the alloy melt are ensured, and the ultrasonic atomizing efficiency is enhanced;
4. the rotary ultrasonic atomization device is externally arranged, only the ultrasonic amplitude transformer is arranged in the atomization tank, the ultrasonic transducer and the shell are both arranged outside the atomization tank, and the shell of the rotary ultrasonic atomization device is provided with the vent holes, so that the transducer can be cooled immediately during operation of the ultrasonic atomization device, and a complex cooling system can be omitted. The problems that in the prior art, an ultrasonic atomization transducer is arranged in an atomization tank, a complex cooling and sealing system is needed, the structure is complex, and the operation and maintenance costs are high are solved;
5. directly acting the uniform mixing gas with controllable oxygen concentration and temperature on the atomized alloy liquid drops through an atomization area cooling device, and realizing accurate control of the cooling speed and the spheroidizing speed of the ultrasonically atomized alloy liquid drops to obtain high-quality solder alloy powder with surface crystalline structure and sphericity;
6. the fluidized sorting device is used for directly sorting and removing the micro powder according to the difference of the sedimentation velocity of the powder with different particle sizes in the atomization process, so that the integrated process of ultrasonic atomization and micro powder sorting is realized;
7. high-quality spherical welding powder products can be produced by adopting a mode of directly sieving or sieving after transferring according to the quality requirements of welding powder produced with different grades and specifications.
The device has simple and reliable structure and is easy to operate and control. The prepared spherical welding powder has good sphericity, smooth and defect-free surface, crystal structure meeting the requirement of solder paste and excellent quality.
Drawings
FIG. 1 is a schematic view of a high quality spherical welding powder apparatus according to the present invention;
FIG. 2 is a schematic view of a rotary ultrasonic atomizing apparatus;
FIG. 3 is a schematic view of an ultrasound device housing;
FIGS. 4-1 and 4-2 are cross-sectional and bottom views of the atomizing area cooling airflow disk in the radial direction;
fig. 5-1 and 5-2 are a cross-sectional view and a top view of a fluidized sort gas flow disk in a radial direction.
Detailed Description
As shown in figure 1, the equipment for preparing high-quality spherical welding powder comprises a hopper-shaped atomizing tank 1, a feeding device arranged on one side of the top of the atomizing tank, a rotary ultrasonic atomizing device 2 arranged at the center of the top of the atomizing tank, a cooling airflow disc 8 arranged in the atomizing tank and positioned at the lower part of the ultrasonic atomizing device, an infrared radiation heater 21 and a fluidization separation airflow disc 20 which are positioned below the cooling airflow disc, an atomizing area cooling device and a fluidization separation device which are arranged outside the atomizing tank, and an ultrasonic screening machine 24 or a turnover tank 25 arranged at the bottom of the atomizing tank. The infrared radiation heater 21 can be installed by welding a mounting bracket in the atomizing tank, and the fluidized separation airflow disk 20 can be sleeved on a mounting base of the infrared radiation heater.
The feeding device comprises a melting material heat preservation furnace 5 and a feeding pipe 7 which is arranged at the bottom of the melting material heat preservation furnace and is communicated with the atomization tank, the melting material heat preservation furnace is of a double-furnace-liner structure and comprises a melting material liner 5-1 and a heat preservation liner 5-2 which are adjacently arranged in a furnace shell and are communicated with each other through a liquid conveying channel 6 at the bottom, the melting material liner and the heat preservation liner are respectively provided with an independent heating temperature control system, and the feeding pipe is provided with a heating temperature control system.
The cooling device for the atomization area comprises a gas thermostat 9, an oxygen content analyzer 10 installed on the thermostat, an oxygen cylinder 12 connected with the gas thermostat through a first branch pipe, an oxygen gas inlet electromagnetic valve 11 arranged on the first branch pipe, a nitrogen cylinder 13 connected with the gas thermostat through a second branch pipe, and a nitrogen gas inlet electromagnetic valve 14 arranged on the second branch pipe, wherein the gas thermostat 9 is connected with a cooling airflow disc 8 through an atomization area cooling airflow pipe 15. The gas thermostat employs a prior art thermostat, either directly commercially available or manufactured by itself according to the prior art.
The fluidization sorting device comprises a cloth bag dust collector 17 communicated with the upper part of the atomizing tank through a micro powder pipe 16 and a circulating fan 18 connected with the cloth bag dust collector through a pipeline, wherein the blowing port of the circulating fan is connected with a fluidization sorting airflow disc 20 through a fluidization sorting airflow pipe 19.
A discharge valve 22 and a feeder 23 are sequentially arranged at a discharge hole at the bottom end of the atomizing tank, and the outlet of the feeder is connected with a feed hole of an ultrasonic screening machine 24 or a turnover tank 25. The discharge valve 22 is a butterfly valve, and the feeder 23 is a star feeder.
The rotary ultrasonic atomization device 2 is shown in fig. 2 and fig. 3 and comprises a shell 2-3, an ultrasonic transducer 2-2 arranged in the shell, a fixing ring 2-8 sleeved at the top end of the shell, an installation frame 2-9 arranged in the fixing ring, a top cover 2-10 arranged at the top end of the fixing ring, a conductive slip ring 2-1 arranged on the top cover, a synchronous belt pulley 2-4 arranged at the bottom end of the shell and sleeved on a central shaft, and an installation flange 2-5 fixedly connected to the bottom of the synchronous belt pulley; the upper end of a central shaft of the ultrasonic transducer is fixedly arranged on the mounting frame 2-9, the lower end of the central shaft of the ultrasonic transducer is fixedly connected with a central shaft of the synchronous belt pulley, and the conductive slip ring 2-1 is connected with the ultrasonic transducer 2-2; the lower end of a central shaft of the synchronous belt pulley is fixedly connected with an ultrasonic amplitude transformer 2-6, the bottom end of the ultrasonic amplitude transformer is connected with a rotary ultrasonic atomizing disc 2-7, and the rotary ultrasonic atomizing disc is horn-shaped with a downward opening; the rotary ultrasonic atomization device is fixed on the top of the atomization tank through a mounting flange 2-5. 2-4 ventilation holes 2-3-1 are uniformly distributed on the shell 2-3 of the rotary ultrasonic atomization device 2 around the cylindrical surface. The driving motor 3 drives the rotary ultrasonic atomization device to rotate through a synchronous belt 4 which is connected with a belt pulley on a motor output shaft and synchronous belt pulleys 2-4; the cooling airflow disc 8 is sleeved on the ultrasonic amplitude transformer 2-6 and is positioned above the ultrasonic atomizing disc 2-7; the ultrasonic amplitude transformer is positioned in the bucket-shaped atomization tank 1, and the ultrasonic transducer 2-2 and the part above the shell 2-3 are positioned outside the bucket-shaped atomization tank. The driving motor is controlled by frequency conversion, and the rotating speed of the driving motor is adjusted according to different brands and specifications of products. The structure that the ultrasonic transducer is arranged in the external design outside the atomizing tank and the shell of the ultrasonic transducer in the rotary ultrasonic atomizing device is provided with the vent hole enables the ultrasonic atomizing device to be cooled when rotating, and a complex cooling system can be omitted. The transducer may be of a prior art construction. Can be purchased directly or manufactured according to the prior art.
The cooling airflow plate 8 is shown in fig. 4-1 and 4-2 and comprises a small circular plate body with an annular inner cavity 8-1 and downward air outlet pipes 8-2 which are radially and uniformly distributed on the bottom surface of the plate body, wherein the downward air outlet pipes are communicated with the annular inner cavity. The fluidized sorting airflow plate 20 is shown in fig. 5-1 and 5-2 and comprises a small circular plate body with an outer ring annular inner cavity 20-1, and upward air outlet pipes 20-2 which are radially and uniformly distributed on the top surface of the outer ring of the plate body, wherein the upward air outlet pipes are communicated with the outer ring annular inner cavity. The diameter of fluidization separation airflow plate 20 is greater than the diameter of cooling airflow plate 8, can form the airflow area that blows upwards and be greater than the airflow area that blows downwards for after the alloy liquid drop cooling balling, the powder particle size is normal distribution, realizes selecting separately the miropowder.
The method for producing the high-quality spherical welding powder by adopting the equipment comprises the following steps:
A. putting the prepared alloy ingot into a melt container 5-1 of a melt holding furnace 5, starting the melt container 5-1 and a heat preservation container 5-2 to heat and setting respective heating temperature control systems, controlling the temperature parameter to be 50-100 ℃ above the liquidus of the alloy, and after the alloy ingot is melted in the melt container, entering the heat preservation container along a liquid conveying channel 6 at the bottom; and continuously adding new materials into the melting container along with the descending of the alloy melting liquid level in the melting container and the ascending of the liquid level in the heat preservation container, so that the alloy liquid level meets the process requirements. The heating temperature control system with the melting material container and the heat preservation container independent from each other is adopted, so that the temperature of the alloy melt in the heat preservation furnace is stable, meanwhile, the alloy melt in the melting material container enters the heat preservation container from the bottom material conveying pipe, and oxidation slag generated when an alloy ingot is melted in the melting material container floats on the surface of the alloy liquid level and cannot enter the heat preservation container, so that the purity of the alloy entering the ultrasonic atomization process is ensured.
B. An infrared radiation heater 21 is started to preheat an ultrasonic rotary ultrasonic atomizing disk 2-7, the flowability of the alloy melt on the atomizing disk is ensured at the beginning of atomization, a discharging pipe 7 is started, a heating temperature control system of the discharging pipe is arranged, the temperature parameter is controlled to be 50-100 ℃ above the alloy liquidus, an ultrasonic vibration power supply of a driving motor 3 and the rotary ultrasonic atomizing device 2 is started simultaneously, the rotary ultrasonic atomizing device starts to rotate and work, and the alloy melt in a heat preservation container is sprayed to the rotary ultrasonic atomizing disk along the outlet of the discharging pipe to start atomization. The rotary ultrasonic atomizing disk is horn-shaped, a plurality of ultrasonic atomizing wave sections are arranged on the rotary ultrasonic atomizing disk and are divided into wave nodes (static sections) and wave crests (vibration sections), the alloy melt is firstly sprayed on the static sections, the alloy melt is in a spiral flow track on the disk surface under the action of rotary centrifugal force and melt gravity, spreading of metal liquid on the static sections is accelerated, spreading of the melt along the circumferential direction and formation of a thin liquid film are promoted, the alloy melt entering the vibration sections has better uniformity and lower liquid film thickness, meanwhile, a high-frequency and high-power ultrasonic vibration power supply and an ultrasonic transducer 2-2 are adopted, fine atomized alloy liquid drops are obtained, the granularity of alloy powder formed subsequently can be greatly reduced, and the productivity and the powder yield of the alloy powder are greatly improved. Rotatory ultrasonic atomization device adopts rotatory disk ultrasonic atomization technology to atomize into the liquid drop that is normal distribution particle diameter with solder alloy melt, can enlarge the atomized surface of traditional atomizing equipment quotation by a less conical surface region, and increase atomizing area can improve atomized alloy melt flow thereupon, improves atomization efficiency.
C. Starting an atomization area cooling device when the alloy melt starts to be atomized, setting an oxygen content control value of an atomization area of an oxygen content analyzer 10, and controlling an oxygen inlet electromagnetic valve 11 and a nitrogen inlet electromagnetic valve 14 which are arranged between an oxygen cylinder 12 and a nitrogen cylinder 13 and a gas thermostat 9 by the oxygen content analyzer according to the set value to realize proportional mixing of oxygen and nitrogen; meanwhile, the control value of the gas thermostat is set, the temperature of the uniformly-mixed gas reaching the process requirement in the gas thermostat is controlled, the uniformly-mixed gas enters an annular inner cavity 8-1 of a cooling airflow disc 8 of an atomization area through a cooling airflow pipe 15 of the atomization area, and the uniformly-mixed gas directly acts on the freshly atomized alloy liquid drops through a downward air outlet pipe 8-2, so that the precise control of the cooling speed and the spheroidizing speed of the ultrasonically atomized alloy liquid drops is realized, and the spherical welding powder is obtained.
D. When the alloy melt starts to be atomized, the fluidization separation device is started, air supplied by the circulating fan 18 enters an outer ring annular inner cavity 20-1 of the fluidization separation airflow disc 20 through the fluidization separation airflow pipe 19, separation airflow is supplied upwards through the upward air outlet pipe 20-2, micro powder is separated, a gas-solid mixed phase containing the micro powder enters the cloth bag dust collector 17 through the micro powder pipe 16, and the filtered gas returns to the circulating fan. The circulating fan adopts variable frequency control to adjust the rotating speed of the circulating fan according to different sedimentation speeds of micro powder of different brands in production, and the fluidized sorting device directly sorts and removes the micro powder with the particle size below 5um in the atomization process according to the sedimentation speed difference of the powder with different particle sizes, so that the integrated process of ultrasonic atomization and micro powder sorting is realized. In the rotary ultrasonic atomization process, after alloy liquid drops are cooled and spheroidized, the particle sizes of the powder are normally distributed, and the powder with different particle sizes is controlled to be in an upward separation airflow speed larger than the settling speed of the micro powder with the particle size smaller than 5um due to different settling speeds, so that the micro powder can be separated.
E. When the alloy melt starts to be atomized, the discharge valve 22 and the feeder 23 are started, and according to the quality requirements of the welding powder for producing different brands and specifications, the spherical welding powder falls into the ultrasonic sieving machine 24 for sieving or enters the turnover tank 25 for subsequent sieving, so that the required high-quality spherical welding powder product is obtained.
Production example 1: producing Sn63Pb37 spherical welding powder. Feeding a Sn63Pb37 alloy ingot, setting the temperature of a melting material holding furnace and a blanking pipe to be 220-230 ℃, starting an infrared radiation heater and setting the temperature to be 200 ℃ to preheat an atomizing disc, starting an ultrasonic vibration power supply and a driving motor, setting the ultrasonic atomizing frequency to be 51.2khz, setting the rotating speed of the rotating motor to be 1100rpm, starting an atomizing area cooling device when Sn63Pb37 alloy melt enters an atomizing cavity and is sprayed to the rotating ultrasonic atomizing disc to start atomizing, setting the oxygen content control value of an oxygen content analyzer to be 120ppm, setting the control value of a gas heating cooling thermostat to be 60 ℃, simultaneously starting a fluidization sorting device when atomizing, setting the rotating speed of a circulating fan to be 500rpm, adopting an intermittent screening process for producing Sn63Pb37 powder, namely collecting atomized powder by adopting a turnover tank and then feeding a screening machine to carry out screening, feeding the powder to the ultrasonic screening machine, wherein the average sphericity of the Sn63Pb37 powder produced by the process is more than 0.95, the surface of the powder is smooth and has no obvious defects, the surface structure presents a coarse Sn-rich phase, the oxygen content is less than 100ppm, and no satellite ball is observed by a microscope.
Production example 2, sn96.5ag3.0cu0.5 spherical welding powder was produced. The method comprises the steps of feeding Sn96.5Ag3.0Cu0.5 alloy ingots, setting the temperature of a melting material heat preservation furnace and a feeding pipe to be 310-320 ℃, the temperature of an infrared radiation heater to be 300 ℃, the ultrasonic atomization frequency to be 50.6khz, setting the rotating speed of a rotating motor to be 1200rpm, setting the oxygen content control value of an oxygen content analyzer to be 140ppm, setting the control value of a gas heating and cooling thermostat to be 30 ℃, setting the rotating speed of a circulating fan to be 410rpm, and adopting a direct screening process for producing Sn96.5Ag3.0Cu0.5 powder, namely directly connecting a star-shaped feeder outlet to an ultrasonic screening machine, wherein the average sphericity of the Sn96.5Ag3.0Cu0.5 powder produced by the process is greater than 0.95, the surface of the powder is smooth and has no defects such as cracking wrinkles, the surface crystalline structure is uniform and fine, the oxygen content is less than 100ppm, and no satellite spheres are observed by a microscope.
Production example 3, pb92.5ag2.5sn5.0 spherical solder powder was produced. A Pb92.5Ag2.5Sn5.0 alloy ingot is fed, the temperature of a melting material holding furnace and a feeding pipe is set to be 380-390 ℃, the temperature of an infrared radiation heater is set to be 350 ℃, the ultrasonic atomization frequency is 49.6khz, the rotating speed of a rotating motor is set to be 1350rpm, the oxygen content control value of an oxygen content analyzer is set to be 110ppm, the control value of a gas heating and cooling thermostat is 50 ℃, the rotating speed of a circulating fan is set to be 680rpm, an intermittent screening process is adopted in the production of the Pb92.5Ag2.5Sn5.0 powder, namely, a turnover tank is adopted to collect atomized powder and then feed the atomized powder to an ultrasonic screening machine for screening, the average sphericity of the Pb92.5Ag2.5Sn5.0 powder produced by the process is greater than 0.95, the surface of the powder is smooth and has no obvious defects, the oxygen content is less than 100ppm, and no satellite ball is observed by a microscope.
Claims (7)
1. The equipment for preparing the high-quality spherical welding powder is characterized by comprising a bucket-shaped atomizing tank (1), a feeding device arranged on one side of the top of the atomizing tank, a rotary ultrasonic atomizing device (2) arranged at the center of the top of the atomizing tank, a cooling airflow disc (8) arranged in the atomizing tank and positioned at the lower part of the ultrasonic atomizing device, an infrared radiation heater (21) and a fluidized separation airflow disc (20) which are positioned below the cooling airflow disc, an atomizing area cooling device and a fluidized separation device which are arranged outside the atomizing tank, and an ultrasonic screening machine (24) or a turnover tank (25) which is arranged at the bottom of the atomizing tank;
the feeding device comprises a melt heat preservation furnace (5) and a feeding pipe (7) which is arranged at the bottom of the melt heat preservation furnace and is introduced into the atomizing tank, the melt heat preservation furnace is of a double-furnace-liner structure and comprises a melt liner (5-1) and a heat preservation liner (5-2) which are adjacently arranged in a furnace shell, the bottoms of the melt liner and the heat preservation liner are communicated through a liquid conveying channel (6), the melt liner and the heat preservation liner are respectively provided with an independent heating temperature control system, and the feeding pipe is provided with a heating temperature control system;
the rotary ultrasonic atomization device (2) comprises a shell (2-3), an ultrasonic transducer (2-2) arranged in the shell, a fixing ring (2-8) sleeved at the top end of the shell, a mounting frame (2-9) installed in the fixing ring, a top cover (2-10) installed at the top end of the fixing ring, a conductive slip ring (2-1) installed on the top cover, a synchronous belt pulley (2-4) arranged at the bottom end of the shell and sleeved on a central shaft, and a mounting flange (2-5) fixedly connected to the bottom of the synchronous belt pulley; the upper end of a central shaft of the ultrasonic transducer is fixedly arranged on the mounting frame (2-9), the lower end of the central shaft of the ultrasonic transducer is fixedly connected with a central shaft of the synchronous belt pulley, and the conductive slip ring (2-1) is connected with the ultrasonic transducer (2-2); the lower end of a central shaft of the synchronous belt pulley is fixedly connected with an ultrasonic amplitude transformer (2-6), the bottom end of the ultrasonic amplitude transformer is connected with a rotary ultrasonic atomizing disc (2-7), and the rotary ultrasonic atomizing disc is in a horn shape with a downward opening; the rotary ultrasonic atomization device is fixed on the top of the atomization tank through a mounting flange (2-5), and a driving motor (3) drives the rotary ultrasonic atomization device to rotate through a synchronous belt (4) sleeved on a synchronous belt pulley (2-4); the cooling airflow disc (8) is sleeved on the ultrasonic amplitude transformer (2-6) and positioned above the rotary ultrasonic atomizing disc (2-7); the ultrasonic amplitude transformer is positioned in the bucket-shaped atomization tank (1), and the ultrasonic transducer (2-2) and the part above the shell (2-3) are positioned outside the bucket-shaped atomization tank;
the cooling device for the atomization area comprises a gas thermostat (9), an oxygen content analyzer (10) arranged on the thermostat, an oxygen cylinder (12) and an oxygen inlet electromagnetic valve (11) which are connected with the gas thermostat, a nitrogen cylinder (13) and a nitrogen inlet electromagnetic valve (14) which are connected with the gas thermostat, and the cooling device for the atomization area is connected with the gas thermostat and a cooling airflow disc (8) through a cooling airflow pipe (15) for the atomization area;
the fluidization sorting device comprises a cloth bag dust collector (17) and a circulating fan (18), wherein the cloth bag dust collector is communicated with the upper part of the atomizing tank through a micro powder pipe (16), the circulating fan is connected with the cloth bag dust collector, and a blowing port of the circulating fan is connected with a fluidization sorting airflow disc (20) through a fluidization sorting airflow pipe (19);
a discharge valve (22) and a feeder (23) are sequentially arranged at a discharge hole at the bottom end of the atomizing tank, and an outlet of the feeder is connected with a feed inlet of an ultrasonic screening machine (24) or a turnover tank (25).
2. The apparatus for preparing high quality spherical welding powder according to claim 1, characterized in that the housing (2-3) of the rotary ultrasonic atomizer (2) is provided with vent holes (2-3-1).
3. The apparatus for preparing high quality spherical welding powder according to claim 1 or 2, characterized in that the cooling gas flow plate (8) comprises a small circular plate body with an annular inner cavity (8-1), and downward gas outlet pipes (8-2) radially and uniformly arranged on the bottom surface of the plate body, and the downward gas outlet pipes are communicated with the annular inner cavity.
4. The apparatus for preparing high quality spherical welding powder according to claim 1 or 2, characterized in that the fluidization separation airflow plate (20) comprises a small circular plate body with an outer ring annular inner cavity (20-1), and upward air outlet pipes (20-2) radially and uniformly arranged on the top surface of the outer ring of the plate body, and the upward air outlet pipes are communicated with the outer ring annular inner cavity.
5. An apparatus for producing high quality spherical welding powder according to claim 1 or 2 characterized in that the diameter of the fluidized sorting air flow plate (20) is larger than the diameter of the cooling air flow plate (8).
6. An apparatus for producing high quality spherical welding powder according to claim 3 characterized in that the diameter of the fluidized sorting flow disk (20) is larger than the diameter of the cooling flow disk (8).
7. The method for producing high-quality spherical welding powder by using the equipment as claimed in any one of claims 1 to 6 is characterized by comprising the following steps:
A. putting the prepared alloy ingot into a melting material liner (5-1) of a melting material heat preservation furnace (5), starting the melting material liner (5-1) and the heat preservation liner (5-2) to heat, setting respective heating temperature control systems, controlling the temperature parameter to be 50-100 ℃ above the liquidus line of the alloy, and after the alloy ingot is melted in the melting material liner, feeding the alloy ingot into the heat preservation liner along a liquid conveying channel (6) at the bottom; continuously adding new materials into the melting container along with the descending of the alloy melting liquid level in the melting container and the ascending of the liquid level in the heat preservation container to ensure that the alloy liquid level meets the process requirements;
B. an infrared radiation heater (21) is started to preheat a rotary ultrasonic atomizing disk (2-7) to ensure the fluidity of an alloy melt at the atomizing disk at the beginning of atomization, a discharging pipe (7) is started and a heating temperature control system is arranged, the temperature parameter is controlled to be 50-100 ℃ above the liquidus line of an alloy, simultaneously, an ultrasonic vibration power supply of a driving motor (3) and the rotary ultrasonic atomizing device (2) is started, the rotary ultrasonic atomizing device starts to rotate, the alloy melt in a heat preservation container is sprayed to the rotary ultrasonic atomizing disk along the outlet of the discharging pipe to start atomization, the alloy melt is firstly sprayed on a static section of the rotary ultrasonic atomizing disk, under the action of the rotating centrifugal force and the gravity of the melt, the alloy melt flows spirally on the disk surface of the atomizing disk and quickly spreads on the static section to form a uniform thin liquid film, and then enters a vibration section of the rotary ultrasonic atomizing disk, forming fine atomized alloy liquid drops under the high-frequency ultrasound of a rotary ultrasonic atomization device;
C. starting an atomization area cooling device when the alloy melt starts to be atomized, setting an oxygen content control value of an atomization area of an oxygen content analyzer (10), controlling an oxygen inlet electromagnetic valve (11) and a nitrogen inlet electromagnetic valve (14) by the oxygen content analyzer according to the set value, and mixing oxygen and nitrogen proportionally; meanwhile, setting a control value of a gas thermostat, controlling the temperature of the mixed gas in the gas thermostat to reach the process requirement, allowing the mixed gas to enter an atomization area cooling airflow disc (8) through an atomization area cooling airflow pipe (15), and directly acting on the freshly atomized alloy liquid drops through a downward air outlet pipe (8-2) to realize accurate control of the cooling speed and the spheroidizing speed of the ultrasonically atomized alloy liquid drops to obtain spherical welding powder;
D. when the alloy melt starts to be atomized, the fluidized separation device is started, air supplied by a circulating fan (18) enters a fluidized separation airflow disc (20) through a fluidized separation airflow pipe (19), separation airflow is supplied upwards through an upward air outlet pipe (20-2) to separate micro powder, a gas-solid mixed phase containing the micro powder enters a bag dust collector (17) through a micro powder pipe (16), and air is returned to the circulating fan after being filtered;
E. when the alloy melt starts to be atomized, a discharge valve (22) and a feeder (23) are started, and the spherical welding powder falls into an ultrasonic screening machine (24) for screening or directly enters a transfer tank (25).
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| CN110666183A (en) * | 2019-11-19 | 2020-01-10 | 衡东县金源铝银粉有限公司 | Atomizing chamber for preparing firework aluminum powder |
| CN113070479A (en) * | 2021-03-18 | 2021-07-06 | 中国科学院力学研究所 | A carousel initial heating device for high temperature metal centrifugation atomizing powder process |
| CN113059170A (en) * | 2021-03-18 | 2021-07-02 | 中国科学院力学研究所 | Rotary table device for preparing small-particle-size powder in metal centrifugal atomization |
| CN113118448A (en) * | 2021-04-12 | 2021-07-16 | 杭州泛索能超声科技有限公司 | Novel rotatory supersound metal powder process equipment |
| CN114052067A (en) * | 2021-11-26 | 2022-02-18 | 山东公社联盟食品有限公司 | Device for spraying freeze-dried fruit and vegetable syrup and application thereof |
| CN117548679B (en) * | 2024-01-09 | 2024-03-22 | 湖南艾缇欧新材料有限公司 | Tin powder preparation equipment and operation method |
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Address after: 650501 No.2, Yunjing Road, information industry base, Kunming Economic and Technological Development Zone, Yunnan Province Patentee after: YUNNAN TIN NEW MATERIAL Co.,Ltd. Address before: 650501 No.2, Yunjing Road, information industry base, Kunming Economic and Technological Development Zone, Yunnan Province Patentee before: YUNNAN TIN MATERIAL Co.,Ltd. |
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