CN111299601A - Device and method for improving spherical rate of metal powder - Google Patents

Device and method for improving spherical rate of metal powder Download PDF

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CN111299601A
CN111299601A CN202010356188.9A CN202010356188A CN111299601A CN 111299601 A CN111299601 A CN 111299601A CN 202010356188 A CN202010356188 A CN 202010356188A CN 111299601 A CN111299601 A CN 111299601A
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metal
powder
metal powder
atomizing
atomizing tower
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周星晨
赵姝媛
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Liaoning Guanda New Material Technology 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
    • 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
    • B22F2009/086Cooling after atomisation
    • B22F2009/0876Cooling after atomisation by gas

Abstract

The invention belongs to the field of metal powder preparation, and particularly relates to a device and a method for improving the spherical rate of metal powder. Compared with the prior art, the invention has the beneficial effects that: the direct current is adopted in the atomization process, the same charges are formed in the atomization tower, charged particles and particles are mutually repelled, the dispersion of large metal liquid drops can be promoted, the collision bonding probability among atomized metal powder is reduced, the refinement of the metal powder can be promoted, and the sphericity rate is improved.

Description

Device and method for improving spherical rate of metal powder
Technical Field
The invention belongs to the field of metal powder preparation, and particularly relates to a device and a method for improving the sphericity rate of metal powder.
Background
The fine spherical metal powder is a raw material for advanced manufacturing technologies such as 3D printing, injection molding, and the like. Gas atomization is an important method for preparing fine spherical metal powder. At present, the additive manufacturing powder material preparation method comprises gas atomization, plasma rotating electrode, plasma torch atomization, plasma spheroidization and the like, wherein the gas atomization is used for preparing materials such as iron-based, aluminum-based, copper-based, cobalt-chromium-based and the like, and the latter methods are used for preparing high-melting-point and high-activity metal powder. Compared with other spherical powder preparation methods, the gas atomization method has the advantages of low operation cost, simple process and suitability for large-scale preparation, but the gas atomization preparation of the powder has the problems of satellite balls, powder adhesion and the like, so that indexes such as flowability, apparent density and the like are limited. Although the gas atomized powder can meet the use requirements of most current additive manufacturing processes, in recent years, with the deepening of the additive manufacturing processes and the application, the requirements of powder materials are continuously improved, but the requirements are limited by the morphology of the powder, and the requirements cannot be met by the traditional gas atomized powder in some occasions. Other methods such as plasma rotating electrode, plasma torch atomization and the like have higher cost for preparing iron-based, aluminum-based, copper-based and other powder materials. Therefore, the preparation method of the high-sphericity metal powder with high efficiency and low cost has important significance.
Researchers have proposed a variety of methods for improving the sphericity of metal powders. One is to improve the sphericity of the powder in the atomization process, including improving the superheat degree of the alloy, increasing the atomization pressure, interfering the atomization airflow, increasing the size of the tank body and the like, but these methods can increase the process instability factors to some extent, and the improvement on the sphericity of the powder is limited. The other is to improve the morphology of the powder by subsequent treatments, such as plasma spheroidization, high energy ball milling, jet milling, etc., but these methods have limitations in terms of cost and efficiency.
The german patent with patent number DE10237213.6 develops a pressure swirl-gas atomization powder process, where the metal melt first passes through a pressure swirl flow-guide tube to form a conical hollow rotating liquid film, which greatly increases the characteristic surface energy of the melt, and then the liquid film and its primary atomization product are expanded to the vicinity of the annular hole or annular gap gas nozzle and secondarily atomized by a high-velocity gas flow. The thickness of the liquid film at the outlet of the draft tube is far lower than the diameter of the outlet hole of the draft tube, so that the pressure cyclone-gas atomization process has higher fine powder yield compared with the traditional gas atomization process. But the design of the pressure rotational flow guide pipe is complex, and the manufacturing cost is high. At present, the technology is mainly used for preparing low-melting-point metal alloy powder such as tin, tin alloy and the like.
The melt atomization efficiency can be effectively improved by multi-energy coupling, and gas-rotary atomization powder preparation technology is developed by Minagawa et al (loaded in Sci. Technol. adv. Mater., vol. 6, page 329, 2005) of the national institute of Material science and Chinese patent publication No. CN 105397100A. The process couples two processes of gas atomization (gas kinetic energy) and rotary disc (mechanical energy) atomization, a melt jet is firstly smashed by low-pressure atomization airflow to form liquid drop spray, the liquid drop spray collides with the rotary disc and uniformly spreads on the disc surface, and then the liquid drop spray is further centrifugally atomized to generate fine liquid drops. Compared with single gas atomization or rotary disc atomization, the gas-rotary atomization process has higher atomization efficiency, the pressure of the used atomization gas is lower, the rotating speed of the rotary disc is also lower, the extreme working state of a single atomization mode is avoided, and the overall design of atomization equipment is complex.
The invention patent with publication number CN106312085A introduces a method for increasing the fine fraction of iron powder, which mainly comprises adding iron oxide powder into high-pressure water. The patent publication No. CN102350497A discloses a method for preparing iron powder with high compression ratio by water atomization. The invention patent with the publication number of CN104249157A introduces a high-efficiency continuous water atomization process method. At present, no corresponding report capable of controlling the flight speed of the liquid drop and prolonging the flight time exists.
Disclosure of Invention
The invention aims to provide a device and a method for improving the sphericity rate of metal powder, overcome the defects of the prior art, and aim to provide a method for prolonging the space time of metal liquid drops in the atomization process.
In order to achieve the purpose, the invention adopts the technical scheme that:
the technical scheme is as follows: a device for improving the spherical rate of metal powder comprises an atomizing tower, a crucible and an atomizer, wherein the atomizing tower is of a vertical structure, and the atomizer is arranged at an inlet at the top of the atomizing tower below the crucible; the bottom of the atomization tower is provided with air holes for blowing in gas with a buffering effect, the air holes are uniformly distributed along the circumference of the bottom of the tank, the number of the air holes is 8-32, the aperture of each air hole is 1-5mm, and the flow rate of the gas is controlled at 0.5-10 NL/min.
The power of the direct current power supply is continuously adjustable within the range of 5-100 kW, and the output current is continuously adjustable within the range of 0-150A.
Insulating layers are arranged among the outer surface of the crucible, the atomizing tower and the metal inner wall.
The insulating layer is any one of a laminate, rubber, plastic, glass, or ceramic layer.
The second technical proposal is that: a production method for improving the sphericity rate of metal powder is characterized by comprising the following steps: the direct current electric field is applied to the inner cavity of the crucible and the inner wall of the atomizing tower through a direct current power supply, so that positive charges with mutual repulsion are generated between particles and/or granules of the liquid metal, the empty time of liquid metal drops is delayed, and the collision bonding probability between metal powder after atomization is reduced, and the method specifically comprises the following production steps:
1) smelting, melting the materials into liquid metal in a vacuum or inert atmosphere by using a smelting furnace;
2) polarization, before the liquid metal is sent into the atomizer to be atomized into metal liquid drops, the inner cavity of the crucible and the metal inner wall of the atomizing tower are both connected with the positive pole of a direct current power supply through a lead, and the negative pole of the direct current power supply is grounded, so that the liquid metal band generates positive charges with the same polarity as the metal inner wall of the atomizing tower;
3) atomizing, wherein liquid metal is sprayed out through a nozzle of an atomizer, and metal liquid drops with positive charges are dispersed and atomized;
4) and cooling, wherein air holes are uniformly distributed on the periphery of the bottom of the atomizing tower, the positively charged metal droplets and the reverse airflow generate heat exchange when flying in the atomizing tower, and the positively charged metal droplets are solidified and cooled along a flying path to form metal powder which falls down to form a small-particle-size sprayer close to the sprayer and a large-particle-size sprayer far away from the sprayer.
The metal powder is any one of stainless steel, tool steel, aluminum alloy, copper alloy, nickel-based high-temperature alloy and titanium alloy.
The metal powder is mainly spherical, and the sphericity ratio is more than 75%.
Aiming at the technical defects of the traditional gas atomization powder preparation, in the gas atomization process, an electric field is introduced, so that metal droplets are attached with charges with the same polarity, certain repulsion force exists among the metal droplets carrying the charges with the same polarity, and the collision among particles can be reduced; secondly, because the inner metal wall and the metal liquid drops have the same charge, the falling process of the liquid drops in the atomizing tower can reduce the collision times with the inner metal wall, thereby prolonging the emptying time of the liquid drops; the irregularly shaped droplets may not be separated into smaller droplets only by the action of the high pressure gas, but due to the charge of the droplets, the droplets can be further decomposed by the action of the repulsive force, which helps to refine and increase the sphericity ratio. The invention increases the collision buffer effect on liquid drops, and when the metal liquid is atomized, gas is blown in through the air holes uniformly arranged on the circumference of the tank bottom, the type of the gas is the same as that of the atomized gas, so that the metal powder has a buffer (reaction force) before rapidly falling to contact the tank bottom and the tank wall, and the spherical rate of the metal powder can be further improved.
Compared with the prior art, the invention has the beneficial effects that: the method for prolonging the emptying time of the metal liquid drops is characterized in that direct current is adopted in the atomization process, the same charges are formed in an atomization tower, charged particles and particles are mutually repelled, the emptying time of the metal liquid drops is prolonged, pollution to metal melt is avoided in the process, large metal liquid drops can be dispersed, the collision bonding probability among atomized metal powder is reduced, the metal powder can be refined, the spherical rate is improved, and the spherical rate is improved from about 50% to over 75%.
Drawings
FIG. 1 is a schematic diagram of an atomization tower of the present invention.
FIG. 2 shows the morphology of the high-silicon soft magnetic powder of example 1 of the present invention.
FIG. 3 morphology of M2 high speed steel powder of example 2 of the invention.
FIG. 4 shows the morphology of GH3625 Ni-based superalloy powder of example 3 of the present invention.
Fig. 5 powder morphology without dc power applied.
In the figure: 1. a direct current power supply; 2. a crucible; 3. a molten metal; 4. a metal inner wall; 5. an atomizing tower; 6. an atomizer; 7. and (4) air holes.
Detailed Description
The preparation process of the present invention is further illustrated below with reference to examples and figures:
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.
Referring to fig. 1, the atomizing tower of the present invention is schematically shown in structure, and includes an atomizing tower 5, a crucible 2 and an atomizer 6, the atomizing tower 5 is a vertical structure, the atomizer 3 is disposed at an inlet at the top of the atomizing tower below the crucible 2, a metal inner wall 4 is disposed in the atomizing tower 5, both the inner cavity of the crucible 2 and the metal inner wall 4 are connected to the positive electrode of a dc power supply 1 through wires, and the negative electrode of the dc power supply 1 is grounded. The power of the DC power supply 1 is continuously adjustable within the range of 5-100 kW, and the output current is continuously adjustable within the range of 0-150A. The bottom of the atomizing tower is provided with air holes 7 for blowing in gas with a buffering effect, the air holes 7 are uniformly distributed along the circumference of the bottom of the tank, the number of the air holes is 8-32, the aperture of the air holes is 1-5mm, the flow rate of the gas is controlled at 0.5-10NL/min, and the pressure is 0.1-0.5 MPa.
Insulating layers are arranged on the outer surface of the crucible 2 and between the atomizing tower 5 and the metal inner wall 4, so that the influence on other instruments, equipment, personnel and the like after the molten metal is electrified is avoided. In an embodiment, the insulating layer may be any one of a laminate, rubber, plastic, glass, or ceramic layer.
Example 1
Preparing the high-silicon soft magnet powder.
1) Smelting, namely melting the materials into high-silicon soft magnetic liquid metal in a vacuum atmosphere by using a smelting furnace; the high-silicon soft magnetic metal components are shown in table 1;
table 1 wt.%
Figure DEST_PATH_IMAGE002
2) Polarizing, namely, a direct-current power supply anode connected with the high-silicon soft magnetic liquid metal, wherein the high-silicon soft magnetic liquid metal and the inner metal wall of the atomizing tower have homopolar positive charges under the power supply effect of the direct-current power supply anode; the power of the direct current power supply is 5kW, and the current is 10A;
3) atomizing, wherein the high-silicon soft magnetic liquid metal meets supersonic gas jet flow surrounding the flow guide nozzle through jet flow, moves at high speed under the pushing and cutting action of high-pressure gas, and disperses and atomizes metal liquid drops with positive charges; the number of the air holes 7 is 32, the aperture of the air hole is 1mm, the gas flow is 0.5NL/min, and the pressure is 0.1 MPa;
4) and cooling, wherein the high-silicon soft magnetic liquid metal with electropositivity generates violent heat exchange with high-speed airflow when flying in the atomization tank body, and is rapidly solidified and cooled into powder.
The gas pressure of the atomizer and the energy of a direct current electric field are controlled according to the material of the high-silicon soft magnetic liquid metal powder, so that the solidified fine powder with the same polarity flies and falls off along a path far away from the unsolidified coarse powder under the action of the electric field force, gravity and the thrust of the atomized gas.
The obtained high-silicon soft magnetic powder was examined, and as shown in fig. 2 and 5, 65% or more of the powder to which a direct current power was applied had an iron powder diameter of 50 μm or less, and the proportion of the powder to which no direct current power was applied was about 50%. Meanwhile, the powder sphericity rate of the applied direct-current power supply is greatly improved to 90%, and the powder sphericity rate of the non-applied powder is about 70%.
Example 2
M2 high speed steel powder was prepared.
1) Smelting, namely melting the materials into M2 high-speed molten steel by using a smelting furnace in a vacuum atmosphere; the main components of the M2 high-speed steel are shown in Table 2;
table 2 wt.%
Figure DEST_PATH_IMAGE004
2) Polarization, wherein an electric field is provided for the molten steel through a positive electrode of a direct current power supply connected with the M2 high-speed molten steel, and positive charges with the same polarity are carried on the M2 high-speed molten steel and the inner metal wall of the atomizing tower under the power supply action of the positive electrode of the direct current power supply; the power of the direct current power supply is 25kW, and the current is 50A; the number of the air holes 7 is 24, the aperture of the air holes is 2mm, the gas flow is 2.5NL/min, and the pressure is 0.2 MPa;
3) atomizing, wherein liquid metal meets supersonic gas jet flow surrounding a flow guide nozzle through jet flow, moves at high speed under the pushing and cutting action of high-pressure gas, and disperses and atomizes metal liquid drops with positive charges;
4) and cooling, wherein when the M2 high-speed steel metal droplets with positive electricity fly in the atomizing tank body, violent heat exchange is carried out between the droplets and the high-speed airflow, and the droplets are rapidly solidified and cooled into powder.
When the obtained M2 high-speed steel powder was examined, as shown in FIGS. 3 and 5, the iron powder diameter was 50 μ M or less for 65% or more of the powder to which the DC power was applied, and the proportion was about 45% for the powder to which no DC power was applied. Meanwhile, the powder sphericity rate of the applied direct-current power supply is greatly improved to over 85 percent, and the powder sphericity rate of the non-applied powder is about 60 percent.
Example 3
Preparing GH3625 nickel-base superalloy powder.
1) Smelting, namely melting the materials into GH3625 nickel-based high-temperature alloy melt by using a smelting furnace in an argon atmosphere; the components of the GH3625 nickel-based superalloy are shown in Table 3;
table 3 wt.%
Figure DEST_PATH_IMAGE006
2) Polarization, wherein an electric field is provided for the metal through a direct current power supply positive electrode in contact with the GH3625 nickel-based superalloy mother liquor, and the GH3625 nickel-based superalloy mother liquor and the inner wall of the metal of the atomizing tower have positive charges with the same polarity under the action of the power supply of the direct current power supply positive electrode; the power of the direct current power supply is 50kW, and the current is 100A; the number of the air holes 7 is 16, the aperture of the air holes is 3mm, the gas flow is 7NL/min, and the pressure is 0.3 MPa;
3) atomizing, wherein a GH3625 nickel-based superalloy mother liquid jet meets a supersonic gas jet surrounding a flow guide nozzle, moves at a high speed under the pushing and cutting action of high-pressure gas, and disperses and atomizes metal droplets with positive charges;
4) and cooling, wherein the GH3625 nickel-based high-temperature alloy mother liquor with electropositivity generates violent heat exchange with high-speed airflow when flying in the atomizing tank body, and is rapidly solidified and cooled into powder.
The obtained GH3625 nickel-base superalloy powder was examined, and as shown in FIGS. 4 and 5, the powder to which a DC power was applied was 68% or more in diameter of iron powder of 50 μm or less, and the proportion of the powder to which no DC power was applied was about 50%. Meanwhile, the powder sphericity rate of the applied direct-current power supply is greatly improved to over 85 percent, and the powder sphericity rate of the non-applied powder is about 65 percent.
Example 4
42CrNiMoV die steel powder is prepared.
1) Smelting, namely melting the materials into 42CrNiMoV die steel metal liquid by using a smelting furnace in an argon atmosphere; the 42CrNiMoV die steel composition is shown in Table 4.
Table 4 wt.%
Figure DEST_PATH_IMAGE008
2) Polarization, namely providing an electric field for the metal through a positive electrode of a direct current power supply in contact with the 42CrNiMoV die steel mother liquor, and carrying out homopolar positive charges on the 42CrNiMoV die steel mother liquor and the inner wall of the metal of the atomizing tower under the action of power supply of the positive electrode of the direct current power supply; the power of the direct current power supply is 100kW, and the current is 150A; the number of the air holes 7 is 8, the aperture of the air holes is 5mm, the gas flow is 10NL/min, and the pressure is 0.5 MPa;
3) atomizing, namely enabling 42CrNiMoV die steel metal liquid to meet supersonic gas jet flow surrounding a flow guide nozzle through jet flow, moving at high speed under the pushing and cutting action of high-pressure gas, and dispersing and atomizing metal liquid drops with positive charges;
4) and cooling, wherein when positively charged 42CrNiMoV die steel liquid drops fly in the atomization tank body, violent heat exchange is carried out between the positively charged 42CrNiMoV die steel liquid drops and high-speed airflow, and the positively charged 42CrNiMoV die steel liquid drops are rapidly solidified and cooled into powder.
The obtained 42CrNiMoV die steel powder was examined, and the powder to which a direct current power was applied had an iron powder diameter of 50 μm or less in an amount of 65% or more, and the powder to which no direct current power was applied had an iron powder diameter of 50% or less. Meanwhile, the powder sphericity rate of the applied direct-current power supply is greatly improved to over 75 percent, and the powder sphericity rate of the not-applied powder is about 55 percent.
The embodiments described above are merely specific examples selected for illustrating the objects, technical solutions and advantages of the present invention in detail, and should not be construed as limiting the scope of the present invention, and various modifications, equivalent substitutions and improvements can be made without departing from the spirit and principle of the present invention.

Claims (7)

1. A device for improving the spherical rate of metal powder comprises an atomizing tower, a crucible and an atomizer, wherein the atomizing tower is of a vertical structure, and the atomizer is arranged at an inlet at the top of the atomizing tower below the crucible; the bottom of the atomization tower is provided with air holes for blowing in gas with a buffering effect, the air holes are uniformly distributed along the circumference of the bottom of the tank, the number of the air holes is 8-32, the aperture of each air hole is 1-5mm, and the flow rate of the gas is controlled at 0.5-10 NL/min.
2. The apparatus of claim 1, wherein the power of the DC power source is continuously adjustable within a range of 5 to 100kW, and the output current is continuously adjustable within a range of 0 to 150A.
3. The apparatus as claimed in claim 1, wherein an insulating layer is provided between the outer surface of the crucible, the atomizing tower and the inner wall of the metal.
4. The apparatus of claim 1, wherein the insulating layer is any one of a laminate, rubber, plastic, glass, or ceramic layer.
5. A production method for improving the sphericity rate of metal powder is characterized by comprising the following steps: the direct current electric field is applied to the inner cavity of the crucible and the inner wall of the atomizing tower through a direct current power supply, so that positive charges with mutual repulsion are generated between particles and/or granules of the liquid metal, the empty time of liquid metal drops is delayed, and the collision bonding probability between metal powder after atomization is reduced, and the method specifically comprises the following production steps:
1) smelting, melting the materials into liquid metal in a vacuum or inert atmosphere by using a smelting furnace;
2) polarization, before the liquid metal is sent into the atomizer to be atomized into metal liquid drops, the inner cavity of the crucible and the metal inner wall of the atomizing tower are both connected with the positive pole of a direct current power supply through a lead, and the negative pole of the direct current power supply is grounded, so that the liquid metal band generates positive charges with the same polarity as the metal inner wall of the atomizing tower;
3) atomizing, wherein liquid metal is sprayed out through a nozzle of an atomizer, and metal liquid drops with positive charges are dispersed and atomized;
4) and cooling, wherein air holes are uniformly distributed on the periphery of the bottom of the atomizing tower, the positively charged metal droplets and the reverse airflow generate heat exchange when flying in the atomizing tower, and the positively charged metal droplets are solidified and cooled along a flying path to form metal powder which falls down to form a small-particle-size sprayer close to the sprayer and a large-particle-size sprayer far away from the sprayer.
6. The method for increasing the sphericity ratio of a metal powder according to claim 5, wherein said metal powder is any one of stainless steel, tool steel, aluminum alloy, copper alloy, nickel-base superalloy, and titanium alloy.
7. The production method for improving the sphericity ratio of metal powder according to claim 5, wherein: the metal powder is mainly spherical, and the sphericity ratio is more than 75%.
CN202010356188.9A 2020-04-29 2020-04-29 Device and method for improving spherical rate of metal powder Withdrawn CN111299601A (en)

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Application publication date: 20200619