CN111069615A - Spherical high-chromium copper alloy powder for 3D printing and preparation method thereof - Google Patents

Spherical high-chromium copper alloy powder for 3D printing and preparation method thereof Download PDF

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CN111069615A
CN111069615A CN201911230238.2A CN201911230238A CN111069615A CN 111069615 A CN111069615 A CN 111069615A CN 201911230238 A CN201911230238 A CN 201911230238A CN 111069615 A CN111069615 A CN 111069615A
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limit position
powder
chromium
copper alloy
bar
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CN111069615B (en
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张飞
高正江
王山
马腾
张建
殷雷
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Avic Maite Additive Technology Beijing Co ltd
Avimetal Powder Metallurgy Technology Xuzhou Co ltd
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China Aviation Maite Fine Metallurgical Technology (xuzhou) Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making 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
    • B22F9/082Making 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 atomising using a fluid
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06Metallic powder characterised by the shape of the particles
    • B22F1/065Spherical particles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00Auxiliary operations or equipment, e.g. for material handling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00Materials specially adapted for additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making 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
    • B22F9/082Making 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 atomising using a fluid
    • B22F2009/0836Making 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 atomising using a fluid with electric or magnetic field or induction
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/02Making metallic powder or suspensions thereof using physical processes
    • B22F9/06Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08Making 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
    • B22F9/082Making 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 atomising using a fluid
    • B22F2009/0848Melting process before atomisation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00Technologies related to metal processing
    • Y02P10/25Process efficiency

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Nanotechnology (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Powder Metallurgy (AREA)

Abstract

The invention provides spherical high-chromium copper alloy powder for 3D printing and a preparation method thereof, wherein the preparation method comprises the following steps: s1 feeding, under the protective gas environment, enabling the bar stock to rotate and move from one limit position to another limit position at a set feeding speed under the drive of a feeding mechanism; s2, smelting, and adjusting the gas pressure state in the system; carrying out vacuum induction melting on the bar stock so as to melt the top conical surface and converging the top conical surface to the top conical tip of the bar stock to form liquid drops; s3 atomizing to prepare powder, and atomizing the liquid drops in an atomizer to obtain metal powder; and S4 grading, namely, carrying out particle size grading treatment on the fully cooled metal powder under the gas protection environment to obtain the high-chromium copper alloy powder meeting the requirement. The powder prepared by the method has low oxygen content and nitrogen content, no inclusion introduction and no macro segregation.

Description

Spherical high-chromium copper alloy powder for 3D printing and preparation method thereof
Technical Field
The invention relates to the technical field of 3D printing and powder metallurgy, in particular to spherical high-chromium copper alloy powder for 3D printing and a preparation method thereof.
Background
The copper-chromium alloy is a high-strength high-conductivity copper alloy material, has good comprehensive performance, and is widely concerned by the electronic, electric, traffic and aerospace industries due to the excellent electrical characteristics of the copper-chromium alloy material. The main characteristics are as follows: compared with other alloy materials, the alloy material has higher strength and better electric and thermal conductivity. At present, the most effective method for improving the strength of the copper-chromium alloy is to increase the chromium content in the alloy, and researches suggest that the size of a chromium-rich phase in the alloy is refined to obtain a supersaturated copper-chromium solid solution which is uniformly distributed in a copper matrix, so that the strength of the material in the alloy is relatively improved, and the conductivity is not greatly changed. The method can improve the alloy strength and ensure the electric and heat conducting performance of the alloy, but provides higher requirements for the preparation of the copper-chromium alloy.
The existing preparation process of the copper-chromium alloy powder adopts a mechanical alloying method and a vacuum melting gas atomization method, wherein the mechanical alloying method mainly grinds pure copper and pure chromium powder through high-energy ball milling, and impurities are inevitably introduced in the ball milling process, so that the powder impurities and gas content are high, and the adverse effect is caused on the performance of subsequent components. The vacuum melting gas atomization method adopts a graphite or ceramic crucible to carry out vacuum or non-vacuum induction melting on raw materials, utilizes a guide pipe to guide molten metal into the center of an atomizing nozzle, and utilizes high-pressure inert gas to crush the molten metal to obtain spherical or spheroidal alloy powder. Because the melting point difference of copper and chromium is large, a large amount of copper is volatilized in the smelting process, so that the burning loss rate of raw materials is high; the density difference between copper and chromium is large, and chromium floats upwards in the smelting process, so that powder is subjected to macro segregation; the copper and chromium raw materials and the crucible material are subjected to chemical reaction at high temperature, so that nonmetallic inclusions are introduced into the powder; along with the increase of the chromium content (wt% is more than 25), the alloy smelting time is prolonged, the viscosity of molten metal is high, and the nozzle blockage is easy to occur in the atomization process, so that the powder preparation process is stopped, and the efficiency is low.
3D printing, also known as "additive manufacturing," has recently risen in the global manufacturing industry due to its innate advantages over traditional manufacturing methods of "flexible manufacturing" and "raw material savings. The blank with the dimensional precision close to that of a finished product can be manufactured by applying the 3D printing technology, and the dimensional precision requirement of the component can be met only by a small amount of machining or no machining, so that the material utilization rate is greatly improved, and the manufacturing cost is reduced. Spherical metal powder is one of the main 3D printing raw materials at present, and the preparation of high-quality spherical copper-chromium alloy powder is a key factor for expanding the 3D printing application of copper-chromium alloy.
Therefore, a spherical high-chromium copper alloy powder for 3D printing with low powder inclusion amount, which does not cause macro segregation, and which is low in cost and high in preparation efficiency is needed.
Disclosure of Invention
The invention mainly aims to provide spherical high-chromium copper alloy powder for 3D printing and a preparation method thereof, the spherical high-chromium copper alloy powder for 3D printing prepared by the method has low oxygen content and nitrogen content, no inclusion introduction, no macro segregation and low preparation cost, and the technical problems of inclusion introduction and powder macro segregation in the process of preparing the spherical high-chromium copper alloy powder for 3D printing in the prior art are solved.
In order to achieve the above object, according to a first aspect of the present invention, there is provided a method of preparing a spherical high-chromium copper alloy powder for 3D printing.
The preparation method of the spherical high-chromium copper alloy powder for 3D printing comprises the following steps:
s1: feeding, namely vacuumizing the interior of the equipment, and then filling protective gas; under the protective gas environment, enabling the bar stock to rotate and move from one limit position to another limit position at a set feeding speed under the drive of a feeding mechanism;
s2: smelting, and adjusting the gas pressure state in the system; carrying out vacuum induction melting on the bar stock so as to melt the top conical surface and converging the top conical surface to the top conical tip of the bar stock to form liquid drops;
s3: atomizing to prepare powder, namely atomizing the liquid drops in an atomizer to obtain metal powder;
s4: and grading, namely performing particle size grading treatment on the fully cooled metal powder in a gas protection environment to obtain high-chromium copper alloy powder with a particle size range meeting different 3D printing requirements.
Further, the method further comprises: s0: preparing a bar stock, namely preparing the bar stock with a conical tip by adopting a vacuum induction casting process or a powder pressing method; wherein:
the content of chromium in the bar stock is 2-50% by mass percent; the diameter of the bar is 20-105 mm, and the length of the bar is 100-1000 mm; the taper angle of the top of the bar is 45-135 degrees, and the diameter of the taper point of the top of the bar is 10-20 mm.
Further, the preparation of the bar stock by adopting a powder pressing method comprises the following steps: carrying out compression molding on the high-chromium copper alloy powder with the granularity range not suitable for the 3D printing process obtained in the step S4 on a hydraulic press to prepare the bar stock meeting the requirement; wherein the electrode density of the bar stock is 85-90% of the solid density.
Further, in the step S1, the feeding mechanism is controlled by a PLC and is provided with three limit positions, which are a first limit position, a second limit position and a third limit position in sequence; the bar stock moves from a first limit position to a second limit position at a set feeding speed and then moves from the second limit position to a third limit position; and when the bar stock moves to the third limit position, stopping feeding and lifting the bar stock to the first limit position for replacement.
Further, in the step S1, the rotation speed of the bar stock is 40-200 r/min, the feeding speed of the bar stock moving from the first limit position to the second limit position is 1000-2000 mm/min, and the feeding speed of the bar stock moving from the second limit position to the third limit position is 20-150 mm/min; the speed of the bar moving from the third limiting position to the first limiting position is 1000-2000 mm/min.
Further, in step S1, the degree of vacuum is 10-210Pa, wherein the protective gas is one or more of nitrogen, argon and helium; the pressure of the protective gas environment is-0.005 Mpa.
Further, in step S2, the adjusting the gas pressure state inside the system includes: when the bar moves from the first limit position to the second limit position, the exhaust fan and the exhaust valve are opened to maintain the interior of the system in a micro-negative pressure state; meanwhile, protective gas with certain pressure is filled into the upper cavity of the nozzle, so that the pressure difference of the upper cavity and the lower cavity of the nozzle is kept at 0.03-0.05 Mpa.
Further, in the step S2, the power of the exhaust fan is 15-22 Kw, the wind pressure is 10000-20000 Pa, and the wind volume is 1000-2000 m3The pressure of a protective gas pipeline introduced into the upper cavity of the nozzle is 0.1-0.3 Mpa, and the flow is 20-100 m3/h。
Further, in the step S2, the vacuum induction melting process adopts a high-frequency heating power supply, and the bar stock is inductively heated by using a conical coil; moving the billet from the second limit position to a third limit position during heating; the conical coil is coaxial with the center hole of the atomizer, the coaxiality is less than or equal to 2mm, and the axial distance is 5-30 mm.
Further, in the step S2, the power of the high-frequency heating power supply is 30-150 Kw, and the frequency is 30-250 KHz; the conical coil has a cone angle of 45-120 degrees, 3-5 turns, a top inner diameter of 45-130 mm and a bottom inner diameter of 25-45 mm.
Further, the step S3 includes:
s3-1: the liquid drops drop by drop or form liquid flow under the action of gravity and the suction force of the nozzle, fall into a central hole of the atomizer and move to an atomized gas gathering point under the action of the suction force of the nozzle and the pressure difference between an upper cavity and a lower cavity in an accelerated manner;
s3-2: the liquid drop or liquid flow is peeled and dispersed in the process of accelerated motion, and meanwhile, the peeled and dispersed liquid film is broken into fine liquid drops in the atomizer through high-pressure inert gas jet flow;
s3-3: and the fine liquid drops perform convection heat exchange with high-pressure inert gas in the flying process, are gradually cooled, and are spheroidized and solidified under the action of surface tension to form metal powder.
Furthermore, the atomizer is of an annular hole or annular seam structure, and a central hole of the atomizer is of a Laval structure; the diameter of an upper opening of the laval structure is 15-25 mm, the diameter of a throat part of the laval structure is 10-15 mm, and the diameter of a lower opening of the laval structure is 20-25 mm.
Further, in step S3, the high-pressure inert gas is one or more of nitrogen, argon, and helium; the atomization pressure is 2-6 Mpa.
In order to achieve the above object, according to a second aspect of the present invention, there is provided a spherical high-chromium copper alloy powder for 3D printing.
The spherical high-chromium copper alloy powder for 3D printing is prepared based on the preparation method of the spherical high-chromium copper alloy powder for 3D printing.
The sphericity of the powder is 0.8-0.96; when the chromium content in the powder is more than 4.5% by mass, a chromium phase is separated out from the surface of the powder, and the size of the chromium phase is less than 1 mu m and is uniformly distributed on the surface of the powder.
The basic principle of the gas atomization method is that liquid metal flow is crushed into small liquid drops by high-speed airflow, and the small liquid drops are cooled and solidified into powder by convective heat transfer in the process, so that the prepared spherical powder has the advantages of high purity, low gas content, controllable granularity and the like.
The invention has the technical effects that:
1. the high-frequency vacuum induction electrode is adopted for smelting in the smelting process, so that the degree of superheat is improved, the yield of fine powder is improved, and the gas content of the powder is reduced;
2. no crucible and flow guide nozzle are used, so that ceramic inclusions are prevented from being introduced;
3. the size of liquid drops is small in the smelting process, so that the segregation is reduced to a certain extent;
4. the liquid drops fall into the central hole of the atomizer under the action of gravity, the suction force of the nozzle and the pressure difference of the chamber, the speed is certain, the nozzle with the Laval structure reduces the risk of nozzle blockage, the surface wave strength of the liquid drops is increased, and the powder making efficiency is improved;
5. the powder with the granularity range which can not meet the 3D printing requirement is prepared into a rod by mould pressing, so that the material utilization rate is improved, and the cost is reduced;
6. the powder grading treatment is carried out under the protection of inert gas, so that the secondary oxygen and nitrogen increasing of the powder is effectively prevented.
Drawings
Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention. Also, like reference numerals are used to refer to like parts throughout the drawings. In the drawings:
FIG. 1 is a schematic flow chart of a method for preparing spherical high-chromium copper alloy powder for 3D printing according to the present invention;
FIG. 2 is a schematic view of the structure of the bar of the present invention;
FIG. 3 is a schematic view of the position of the bar in the first limit position according to the present invention;
FIG. 4 is a schematic view of the position of the bar in the second limit position according to the present invention;
FIG. 5 is a schematic view of the position of the bar in the third limit position according to the present invention;
FIG. 6 is a macro topography of spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method in the embodiment of the invention;
FIG. 7 is a micro-topography of spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method in the embodiment of the invention;
fig. 8 is a powder surface photograph of the spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method in the example of the present invention.
In the figure:
1. a bar stock; 2. smelting a coil; 3. an atomizing nozzle.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
The invention discloses a preparation method of spherical high-chromium copper alloy powder for 3D printing, and fig. 1 is a schematic flow chart of the preparation method of the spherical high-chromium copper alloy powder for 3D printing provided in the embodiment of the invention, and as shown in fig. 1, the preparation method mainly comprises the following steps:
step S0, preparing a copper-chromium alloy rod from the copper-chromium alloy by adopting a vacuum induction fusion casting process to be used as an induction electrode, and then processing the head of the copper-chromium alloy rod to the size shown in figure 2 to form a bar stock with a conical tip; or preparing a bar with a conical tip by adopting a powder pressing method; wherein the chromium content in the bar is 2-50% by mass; the diameter of the bar is 20-105 mm, and the length of the bar is 100-1000 mm; the taper angle at the top of the bar is 45-135 degrees, and the diameter of the taper point at the top of the bar is 10-20 mm.
The preparation of the bar stock by the powder pressing method specifically comprises the following steps: carrying out compression molding on the high-chromium copper alloy powder with the granularity range not suitable for the 3D printing process obtained in the step S4 on a hydraulic press to prepare the electrode bar material meeting the requirement; wherein the pressure of the hydraulic press is 50-100 tons, the effective working area is not less than 650 multiplied by 650mm, and the diameter of the die is 50-150 mm; the electrode density of the prepared bar is 85-90% of the solid density, so that material recycling is realized, the material utilization rate is improved, and the cost is obviously reduced.
Step S1, vacuumizing the interior of the equipment, and filling inert gas into the equipment when the vacuum degree reaches a certain degree; in the inert gas protection environment, the bar stock is made to rotate at the speed of 40-200 r/minThe device rotates automatically and moves from one limit position to another limit position under the drive of a feeding mechanism; wherein: the vacuum degree in the apparatus was 10-2-10 Pa; the inert gas is one or a mixture of nitrogen, argon and helium; the pressure of the inert gas protective environment is-0.005 Mpa;
the feeding mechanism is controlled by a PLC and is provided with three limiting positions, namely a first limiting position, a second limiting position and a third limiting position in sequence, as shown in figures 3-5; the bar moves from the first limiting position to the second limiting position at a feeding speed of 1000-2000 mm/min, and then moves from the second limiting position to the third limiting position at a feeding speed of 20-150 mm/min.
It should be noted that when the bar stock is heated and melted to the third limit position (as shown in fig. 5), the continuous feeding is automatically stopped, and the melting power supply, the exhaust fan, the exhaust valve and the atomizing gas are turned off. If the feeding is needed to be continued, the bar stock is lifted to the first limit position at the movement speed of 1000-2000 mm/min for replacement, and then the steps S1-S5 are repeated.
Step S2, when the bar moves from the first limit position to the second limit position, as shown in fig. 3 and 4, the exhaust fan and the exhaust valve are opened to maintain the interior of the system in a micro-negative pressure state; meanwhile, protective gas with certain pressure is filled into the upper cavity of the nozzle, so that the pressure difference of the upper cavity and the lower cavity of the nozzle is kept between 0.03 and 0.05 Mpa; wherein the power of the air exhaust fan is 15-22 Kw, the air pressure is 10000-20000 Pa, and the air volume is 1000-2000 m3The pressure of a protective gas pipeline introduced into the upper cavity of the nozzle is 0.1-0.3 Mpa, and the flow is 20-100 m3/h;
Then starting a high-frequency heating power supply, carrying out induction heating on the copper-chromium alloy electrode bar by using a conical coil, gradually melting the conical surface at the top of the bar, and gradually converging the conical surface to the conical tip at the top of the bar under the action of viscous force, gravity and coil electromagnetic force to form liquid drops; wherein:
the power of the high-frequency heating power supply is 30-150 Kw, and the frequency is 30-250 KHz; the conical coil has a cone angle of 45-120 degrees, 3-5 turns, a top inner diameter of 45-130 mm and a bottom inner diameter of 25-45 mm;
the conical coil is arranged above the atomizer, is coaxial with a center hole of the atomizer, and has the coaxiality less than or equal to 2mm and the axial distance of 5-30 mm.
Step S3, when the top electromagnetic force is weakened, the nozzle suction force on the liquid drops is gradually increased, and the liquid drops or forms liquid flow to fall into the central hole of the atomizer below the conical coil under the action of gravity and the nozzle suction force;
the liquid drops or liquid flow in the central hole moves to the convergence point of the atomized gas in an accelerated manner under the action of the suction force of the nozzle and the pressure difference of the upper cavity and the lower cavity;
the liquid drops or liquid flow are peeled and dispersed under the action of the turbulence of surrounding air flow in the process of accelerated motion, and meanwhile, the peeled and dispersed liquid film is crushed into fine liquid drops by high-pressure inert gas jet flow in the atomizer;
carrying out convection heat exchange on the fine liquid drops and high-pressure inert gas in the flying process, gradually cooling, and spheroidizing and solidifying under the action of surface tension to obtain metal powder;
wherein:
the high-pressure inert gas is one or a mixture of nitrogen, argon and helium; the atomization pressure is 2-6 Mpa; the atomizer is a circular hole or circular seam structure, the central hole of the atomizer is of a Laval structure, the diameter of an upper opening of the Laval structure is 15-25 mm, the diameter of a throat part of the Laval structure is 10-15 mm, and the diameter of a lower opening of the Laval structure is 20-25 mm.
It should be noted that, because the central hole of the atomizer is of a laval structure, liquid drops enter the diffusion section after passing through the throat part, and a liquid film or a liquid band is generated on the surface of the liquid drops in the central hole under the change of the state of surrounding air flow, thereby being beneficial to atomization and crushing; in addition, the increase in the diameter of the laval structure diffuser section also reduces to some extent the risk of droplets clogging the nozzle.
And step S4, under the gas protection environment, carrying out particle size grading treatment on the fully cooled copper-chromium alloy powder to obtain high-chromium copper alloy powder with the particle size range meeting different 3D printing process requirements.
The invention also discloses spherical high-chromium copper alloy powder for 3D printing, which is prepared by the preparation method, as shown in figures 6-8, the powder is spherical or nearly spherical, and the sphericity is 0.8-0.96; and the powder phase composition is supersaturated copper chromium phase (fcc), when the chromium content is more than 4.5% (mass ratio), the chromium phase is separated out on the powder surface, and the size is less than 1 μm and is uniformly distributed on the powder surface.
The production method of the present invention will be described in detail with reference to specific examples.
Example 1:
step S0, processing the vacuum induction casting copper-chromium alloy bar with 40 percent (mass ratio) of chromium content into an electrode bar with the diameter of 40mm, the length of 600mm, the taper angle of one end of the bar of 90 degrees and the tip diameter of one end of the taper angle of 15mm, and mounting the bar on a feeding device.
Step S1, vacuumizing the whole equipment with the vacuum degree of 10-1Pa, and filling argon for protection, wherein the pressure of the argon for protecting the environment is-0.005 Mpa; the electrode bar stock moves from the first limit position to the second limit position at a rotating speed of 140r/min and a descending speed of 1000 mm/min.
Step S2, opening an exhaust fan and an exhaust valve to maintain the interior of the system in a micro negative pressure state, and simultaneously filling gas into an upper cavity of the atomizer to keep the pressure difference between an upper cavity and a lower cavity at 0.03-0.05 Mpa; wherein the power of the exhaust fan is 15Kw, the wind pressure is 15000Pa, and the wind volume is 1500m3H, the pressure of a protective gas pipeline introduced into the upper cavity of the nozzle is 0.2Mpa, and the flow is 60m3/h;
And then starting a high-frequency heating power supply, wherein the power of the high-frequency heating power supply is 150Kw, the frequency is 150KHz, a conical coil is used for carrying out induction heating on the copper-chromium alloy electrode bar, the conical angle of the conical coil is 80 degrees, the number of turns is 4, the inner diameter of the top is 80mm, the inner diameter of the bottom is 30mm, the conical surface of the top of the bar is gradually melted under the induction heating action in the conical coil and gradually converged to the conical tip of the top of the bar under the action of viscous force, gravity and coil electromagnetic force to form liquid drops, and the bar moves from the second limit position to the third limit position at the feeding speed of 20mm/min in the heating process.
Step S3, starting atomizing gas, wherein the pressure of the atomizing gas is 4.5MPa, liquid flow formed under the action of gravity and the suction force of a nozzle falls into a central hole of the atomizer below a conical coil, high-pressure argon enters the annular seam type atomizer through a gas path pipeline, the central hole of the atomizer is of a Laval structure, the diameter of an upper opening of the Laval structure is 20mm, the diameter of a throat part of the Laval structure is 15mm, and the diameter of a lower opening of the Laval structure is 25 mm; the liquid film is peeled and dispersed in the process of accelerating movement of the liquid flow, and meanwhile, the peeled and dispersed liquid film is crushed into fine liquid drops by high-pressure inert gas jet flow in the atomizer; the small liquid drops carry out convection heat exchange with high-pressure inert gas in the flying process of the atomizing chamber, are gradually cooled, and are spheroidized and solidified through the surface tension of the small liquid drops to form copper-chromium alloy powder.
And step S4, performing particle size grading treatment on the fully cooled copper-chromium alloy powder under the argon protection environment to obtain high-chromium copper alloy powder with a particle size range suitable for different 3D printing process requirements.
Example 2:
the preparation method in example 2 is the same as that in example 1, except that the preparation process parameters are different, specifically as follows:
in step S0, the bar is an electrode rod processed by copper-chromium alloy with a chromium content of 50% (mass ratio) and having a diameter of 105mm and a length of 1000mm, and the taper angle at one end of the bar is 135 ° and the tip diameter at one end of the taper angle is 20 mm;
in step S1, the electrode bar stock moves from the first limit position to the second limit position at a rotating speed of 40r/min and a descending speed of 2000 mm/min;
in step S2, the power of the exhaust fan is 22Kw, the wind pressure is 10000Pa, and the wind volume is 1000m3H, the pressure of a protective gas pipeline introduced into the upper cavity of the nozzle is 0.1Mpa, and the flow is 20m3H; the power of a high-frequency heating power supply is 30Kw, the frequency is 250KHz, a conical coil is used for carrying out induction heating on the copper-chromium alloy electrode bar, the conical angle of the conical coil is 45 degrees, the number of turns of the conical coil is 3 turns, the inner diameter of the top is 45mm, and the inner diameter of the bottom is 25 mm; the bar stock is fed at a feed rate of 150mm/min during heatingMoving from the second limit position to a third limit position;
in step S3, the atomizing gas pressure is 2MPa, the upper opening diameter of the Laval structure is 15mm, the throat diameter is 10mm, and the lower opening diameter is 20 mm.
Example 3:
the preparation method in example 3 is the same as that in example 1, except that the preparation process parameters are different, specifically as follows:
in step S0, the high chromium copper alloy powder with the particle size range not suitable for the 3D printing process obtained in example 2 is subjected to compression molding on a hydraulic press to prepare an electrode bar meeting the requirements; wherein the pressure of the hydraulic press is 80 tons, the effective working area is not less than 650 multiplied by 650mm, and the diameter of the die is 100 mm; the electrode density of the prepared bar stock is 90% of the solid density; the diameter of the bar is 20mm, the length is 100mm, the taper angle at one end of the bar is 45 degrees, and the diameter of the tip at one end of the taper angle is 10 mm;
in step S1, the electrode bar stock moves from the first limit position to the second limit position at the rotating speed of 200r/min and the descending speed of 1500 mm/min;
in step S2, the power of the exhaust fan is 18Kw, the wind pressure is 20000Pa, and the wind volume is 2000m3H, the pressure of a protective gas pipeline introduced into the upper cavity of the nozzle is 0.3Mpa, and the flow is 100m3H; the power of a high-frequency heating power supply is 100Kw, the frequency is 30KHz, a conical coil is used for carrying out induction heating on the copper-chromium alloy electrode bar, the conical angle of the conical coil is 120 degrees, the number of turns is 5 turns, the inner diameter of the top is 130mm, and the inner diameter of the bottom is 45 mm; moving the bar stock from the second limit position to a third limit position at a feed rate of 80mm/min during the heating;
in step S3, the atomizing gas pressure is 6MPa, the upper opening diameter of the Laval structure is 25mm, the throat diameter is 15mm, and the lower opening diameter is 25 mm.
The spherical high-chromium copper alloy powder for 3D printing prepared in the embodiments 1-3 of the invention is subjected to component detection, and the chromium content in the powder with the granularity of 15-53 mu m is 38.94% by the component detection, which shows that the preparation method can be used for preparing the high-chromium copper chromium alloy powder. And the oxygen content of the copper-chromium powder with the grain size of 15-53 mu m is 380ppm and the nitrogen content is 25ppm through gas content detection. Ceramic inclusions in a 15-53 mu m particle size section are detected by a water elutriation method, and ceramic inclusions do not exist in 1Kg of sample powder.
Fig. 6 is a macro-photograph of the spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method in the embodiment of the invention, and as can be seen from fig. 6, the powder has consistent color and luster, and no copper-chromium separation is seen.
Fig. 7 is an electron micrograph of the spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method in the embodiment of the invention, and as can be seen from fig. 7, the powder particles are spherical or nearly spherical, there is substantially no adhesion between the particles, and there are few satellite particles.
Fig. 8 is a surface electron microscope photograph of spherical high-copper chromium alloy powder particles for 3D printing prepared by the preparation method in the embodiment of the invention, and it can be seen from fig. 8 that fine chromium particles are uniformly distributed on the surface of the alloy powder. This shows that the spherical high-copper chromium alloy powder for 3D printing prepared by the preparation method of the invention has uniform components at a certain microscopic scale.
To better illustrate that the preparation method in example 1 can be used to obtain spherical high-chromium copper alloy powder for 3D printing with good performance, the invention performs a comparative test, which is specifically described as follows.
Comparative example 1:
the preparation process is the same as that of the example 2, except that a medium-frequency induction furnace is adopted to melt the copper material and the chromium material in the ceramic crucible according to a certain proportion in the atmospheric environment during the melting process, and the atomization pressure is the same as that of the example 2 to atomize and prepare powder after the melting is finished.
Comparative example 2:
the chromium-copper-chromium alloy powder is prepared by adopting the copper-chromium alloy powder preparation method disclosed in Chinese patent 201811393159.9.
And (3) experimental test:
first, experimental object
The experimental group was the powder obtained by the preparation method in examples 1 to 3; the control group was the powder obtained by the preparation method of comparative examples 1 to 2.
Second, Experimental methods
In examples 1 to 3 and comparative examples 1 to 2, the particle size, sphericity, oxygen content, nitrogen content, inclusion content, and the like of the prepared powder were measured by the same test method as in the prior art.
Third, experimental results
The test results of examples 1-3 and comparative examples 1-2 were counted and are detailed in Table 1.
TABLE 1
Figure BDA0002303340370000161
As can be seen from Table 1, the yield of the spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method provided by the invention with the particle size of 15-53 microns reaches 68%, and the maximum chromium content of the spherical high-chromium copper alloy powder with the particle size of 15-53 microns is 48.68%, which indicates that the preparation method provided by the invention can be used for preparing the high-chromium copper chromium alloy powder.
By gas content detection, the oxygen content of the copper-chromium powder with the grain size of 15-53 mu m is within 380ppm, and the nitrogen content is within 38 ppm. Obviously, the high-chromium copper alloy powder prepared by the method has extremely low gas content, and is more beneficial to the improvement of the rear-end application process performance.
And then detecting ceramic inclusions in the 15-53 mu m particle size section by using a water elutriation method, wherein ceramic inclusions do not exist in 1Kg sample powder. Compared with the comparative example 2, in the comparative example 2, the ceramic crucible is used for smelting copper and chromium raw materials, and the superheat degree needs to be 170 ℃, chromium can chemically react with crucible materials at high temperature, and molten metal can erode the crucible wall in the electromagnetic stirring process, so that finally prepared metal powder is mixed with ceramic inclusions. In addition, in the atomization process, the comparative example 2 adopts helium-argon mixed gas as inert gas, the atomization pressure is 15Mpa which is greatly higher than the pressure used in the invention, and the heating temperature of the flow guide nozzle needs to be controlled in the atomization process, so that the flow is complex and is not easy to master.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.

Claims (10)

1. A preparation method of spherical high-chromium copper alloy powder for 3D printing is characterized by comprising the following steps:
s1: feeding, namely vacuumizing the interior of the equipment, and then filling protective gas; under the protective gas environment, enabling the bar stock to rotate and move from one limit position to another limit position at a set feeding speed under the drive of a feeding mechanism;
s2: smelting, and adjusting the gas pressure state in the system; carrying out vacuum induction melting on the bar stock so as to melt the top conical surface and converging the top conical surface to the top conical tip of the bar stock to form liquid drops;
s3: atomizing to prepare powder, namely atomizing the liquid drops in an atomizer to obtain metal powder;
s4: and grading, namely performing particle size grading treatment on the fully cooled metal powder in a gas protection environment to obtain high-chromium copper alloy powder with a particle size range meeting different 3D printing requirements.
2. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 1, further comprising: s0: preparing a bar stock, namely preparing the bar stock with a conical tip by adopting a vacuum induction casting process or a powder pressing method; wherein:
the content of chromium in the bar stock is 2-50% by mass percent; the diameter of the bar is 20-105 mm, and the length of the bar is 100-1000 mm; the taper angle of the top of the bar is 45-135 degrees, and the diameter of the taper point of the top of the bar is 10-20 mm.
3. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 2, wherein the step of preparing the bar stock by adopting a powder pressing method comprises the following steps: carrying out compression molding on the high-chromium copper alloy powder with the granularity range not suitable for the 3D printing process obtained in the step S4 on a hydraulic press to prepare the bar stock meeting the requirement; wherein the electrode density of the bar stock is 85-90% of the solid density.
4. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 1, wherein in the step S1, the feeding mechanism is controlled by a PLC and is provided with three limit positions, namely a first limit position, a second limit position and a third limit position; the bar stock moves from a first limit position to a second limit position at a set feeding speed and then moves from the second limit position to a third limit position; and when the bar stock moves to the third limit position, stopping feeding and lifting the bar stock to the first limit position for replacement.
5. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 4, wherein in the step S1, the autorotation speed of the bar is 40-200 r/min, the feeding speed of the bar moving from the first limit position to the second limit position is 1000-2000 mm/min, and the feeding speed of the bar moving from the second limit position to the third limit position is 20-150 mm/min; the speed of the bar moving from the third limiting position to the first limiting position is 1000-2000 mm/min.
6. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 1, wherein in the step of S2, the adjusting the gas pressure state inside the system comprises: when the bar moves from the first limit position to the second limit position, the exhaust fan and the exhaust valve are opened to maintain the interior of the system in a micro-negative pressure state; meanwhile, protective gas with certain pressure is filled into the upper cavity of the nozzle, so that the pressure difference of the upper cavity and the lower cavity of the nozzle is kept at 0.03-0.05 Mpa.
7. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 6, wherein in step S2, the vacuum induction melting process adopts a high-frequency heating power supply and utilizes a conical coil to perform induction heating on the bar stock; moving the billet from the second limit position to a third limit position during heating; the conical coil is coaxial with the center hole of the atomizer, the coaxiality is less than or equal to 2mm, and the axial distance is 5-30 mm.
8. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 1, wherein the step S3 includes:
s3-1: the liquid drops drop by drop or form liquid flow under the action of gravity and the suction force of the nozzle, fall into a central hole of the atomizer and move to an atomized gas gathering point under the action of the suction force of the nozzle and the pressure difference between an upper cavity and a lower cavity in an accelerated manner;
s3-2: the liquid drop or liquid flow is peeled and dispersed in the process of accelerated motion, and meanwhile, the peeled and dispersed liquid film is broken into fine liquid drops in the atomizer through high-pressure inert gas jet flow;
s3-3: and the fine liquid drops perform convection heat exchange with high-pressure inert gas in the flying process, are gradually cooled, and are spheroidized and solidified under the action of surface tension to form metal powder.
9. The method for preparing spherical high-chromium copper alloy powder for 3D printing according to claim 8, wherein the atomizer is of a ring hole or ring seam structure, and a central hole of the atomizer is of a Laval structure; the diameter of an upper opening of the laval structure is 15-25 mm, the diameter of a throat part of the laval structure is 10-15 mm, and the diameter of a lower opening of the laval structure is 20-25 mm.
10. The spherical high-chromium copper alloy powder for 3D printing prepared by the preparation method of the spherical high-chromium copper alloy powder for 3D printing according to any one of claims 1 to 9, wherein the sphericity of the powder is 0.8 to 0.96; when the chromium content in the powder is more than 4.5% by mass, a chromium phase is separated out from the surface of the powder, and the size of the chromium phase is less than 1 mu m and is uniformly distributed on the surface of the powder.
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