CN112024903A - Metal powder manufacturing equipment and method - Google Patents

Metal powder manufacturing equipment and method Download PDF

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Publication number
CN112024903A
CN112024903A CN202011238748.7A CN202011238748A CN112024903A CN 112024903 A CN112024903 A CN 112024903A CN 202011238748 A CN202011238748 A CN 202011238748A CN 112024903 A CN112024903 A CN 112024903A
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metal powder
coarse
powder
inert gas
size
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CN112024903B (en
Inventor
孙念光
陈斌科
向长淑
朱纪磊
贺卫卫
凤治华
王冬冬
王超
康鑫
张伟
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Xi'an Sailong Additive Technology Co ltd
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Xi'an Sailong Metal Materials Co ltd
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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
    • B22F9/14—Making metallic powder or suspensions thereof using physical processes using electric discharge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
    • B07B—SEPARATING SOLIDS FROM SOLIDS BY SIEVING, SCREENING, SIFTING OR BY USING GAS CURRENTS; SEPARATING BY OTHER DRY METHODS APPLICABLE TO BULK MATERIAL, e.g. LOOSE ARTICLES FIT TO BE HANDLED LIKE BULK MATERIAL
    • B07B1/00—Sieving, screening, sifting, or sorting solid materials using networks, gratings, grids, or the like
    • B07B1/04—Stationary flat screens
    • 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
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/06—Metallic powder characterised by the shape of the particles
    • B22F1/065—Spherical particles

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

Abstract

The invention relates to a metal powder manufacturing device and a method thereof. The equipment comprises a primary powder making device, wherein the primary powder making device comprises a first atomizing chamber and a screening component for screening metal powder into metal powder with a coarse particle size and metal powder with a fine particle size according to a preset size; the secondary powder making device comprises a second atomizing chamber and a heating component and is used for decomposing the coarse-grain-size metal powder; the powder feeding assembly is respectively communicated with the first atomizing chamber and the second atomizing chamber and is used for conveying the screened coarse-grain-size metal powder to the second atomizing chamber; and an inert gas supply system for providing a protective atmosphere in the first atomization chamber and the second atomization chamber and decomposing the coarse-particle-size metal powder by blowing an inert gas to the heated coarse-particle-size metal powder. The invention can continuously carry out powder preparation for two times on the metal bar, thereby improving the collection rate of the metal powder with fine particle size.

Description

Metal powder manufacturing equipment and method
Technical Field
The invention relates to the technical field of atomization powder preparation, in particular to metal powder manufacturing equipment and a metal powder manufacturing method.
Background
In recent years, with the development of powder metallurgy technologies such as hot isostatic pressing, metal additive manufacturing, injection molding and the like, the demand for metal powder is rapidly increased; particularly, with the development of new technologies such as metal additive manufacturing technology, higher requirements are put on the quality of metal powder, especially on the particle size distribution, and the requirements of 3D printing technology represented by selective melting and forming of a powder bed on the particle size of metal powder are mainly focused on 15-100 μm.
In the related technology, a plasma rotating electrode powder preparation technology is a spherical metal powder preparation technology based on a high-speed rotating centrifugal atomization principle, and the main working principle is that a high-temperature heat source acts on an electrode bar rotating at a high speed to melt the end face of the electrode bar to form a liquid film, the liquid film is thrown out under the action of the high-speed rotating centrifugal force to form a liquid line, the liquid line is cooled in an inert atmosphere, and spherical powder is formed under the action of surface tension. The particle size of the metal powder prepared by the plasma rotating electrode powder making technology is distributed between 20 and 250 mu m, and the thicker powder particle size limits the application of the technology in the field of new materials represented by additive manufacturing.
With regard to the above technical solutions, the inventors have found that at least some of the following technical problems exist: the traditional rotary electrode powder manufacturing technology is limited by technical bottlenecks such as the ultimate working rotating speed of equipment, the diameter of an electrode bar and the like, and the particle size of the produced metal powder is concentrated at 20-250 mu m. Taking titanium alloy powder as an example, the yield of the rotary electrode powder with the particle size of less than 100 μm is less than 40%, and the thicker powder particle size limits the application of the rotary electrode powder manufacturing technology in the field of 3D printing.
Accordingly, there is a need to ameliorate one or more of the problems with the related art solutions described above.
It is noted that this section is intended to provide a background or context to the inventive concepts recited in the claims. The description herein is not admitted to be prior art by inclusion in this section.
Disclosure of Invention
An object of the present invention is to provide a metal powder manufacturing apparatus and a method thereof, which overcome, at least to some extent, one or more of the problems due to the limitations and disadvantages of the related art.
First, according to the present invention, there is provided a metal powder manufacturing apparatus including:
the primary powder making device is used for making metal bars into metal powder and comprises a first atomizing chamber and a screening component for screening the metal powder into metal powder with a coarse particle size and metal powder with a fine particle size according to a preset size;
the secondary powder making device comprises a second atomizing chamber and a heating component and is used for decomposing the coarse-grain-size metal powder;
the powder feeding assembly is respectively communicated with the first atomizing chamber and the second atomizing chamber and is used for conveying the sieved metal powder with the coarse particle size to the second atomizing chamber; and
an inert gas supply system in communication with the first atomization chamber, the second atomization chamber, and the heating assembly, the inert gas supply system configured to provide a protective atmosphere in the first atomization chamber and the second atomization chamber and to decompose the heated coarse-grained metal powder by blowing an inert gas thereto;
wherein the heating unit is provided in a communication path between the powder feeding unit and the second atomizing chamber, and heats the coarse-grained metal powder to a state where the coarse-grained metal powder starts to melt before the coarse-grained metal powder is decomposed.
Preferably, the screen assembly comprises a screen having a diameter of 100 μm.
Preferably, the top of the second atomization chamber is provided with a cylindrical interface, the cylindrical interface is provided with an interlayer, and the heating assembly is arranged in the interlayer of the cylindrical interface.
Preferably, the inert gas supply system includes, inert gas source, low pressure give vent to anger the end and the high pressure end of giving vent to anger, inert gas source be used for to the low pressure give vent to anger the end with the high pressure give vent to anger the end and supply inert gas, the low pressure give vent to anger the end respectively with first atomizer chamber with the second atomizer chamber intercommunication, the high pressure give vent to anger the end with the second atomizer chamber intercommunication, wherein, the high pressure give vent to anger the end set up in heating element's below.
Preferably, the height range of the heating assembly is 10-200 mm, the diameter range is 2-100 mm, and the power range is 1-1000 kW.
Preferably, the height, diameter and operating power of the heating assembly are related to the material and particle size of the coarse-grained metal powder.
Preferably, the powder feeding speed of the powder feeding assembly is 10-10000 g/min, and is related to the working power of the heating assembly.
Secondly, according to the present invention, there is also provided a method for manufacturing metal powder, comprising the steps of:
providing a protective atmosphere through the inert gas supply system;
in the protective atmosphere, preparing metal bar stock into the metal powder by the primary powder preparing device;
sieving the metal powder into a coarse-size metal powder and a fine-size metal powder by the sieve assembly;
conveying the coarse-grained metal powder to the second atomization chamber through the powder feeding assembly;
heating, by the heating assembly, the coarse-grained metal powder to a state that begins to melt before the coarse-grained metal powder is decomposed in the protective atmosphere;
blowing an inert gas to the heated coarse-particle-size metal powder by the inert gas supply system in the protective atmosphere to decompose the coarse-particle-size metal powder;
wherein the coarse-grained metal powder in a state of starting to melt has an outer portion in a liquid state and an inner portion in a solid state.
Preferably, the heated coarse-particle-size metal powder is blown with an inert gas at a pressure of 3 to 8Mpa and a speed of 50 to 800m/s by an inert gas supply system, so that the liquid outer portion is separated from the solid inner portion.
Preferably, the powder feeding speed of the powder feeding assembly and the operating power of the heating assembly are adjusted for metal powders of different materials and particle sizes.
The technical scheme provided by the invention can have the following beneficial effects:
according to the equipment and the method, on one hand, the metal bar is continuously subjected to powder making twice, so that the collection rate of fine-grain-size metal powder is improved; on the other hand, the method has the advantages of high sphericity, good fluidity and good compressibility of the metal powder, and has the characteristics of high efficiency, good quality and good batch consistency.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present disclosure and together with the description, serve to explain the principles of the disclosure. It is to be understood that the drawings in the following description are merely exemplary of the disclosure, and that other drawings may be derived from those drawings by one of ordinary skill in the art without the exercise of inventive faculty.
FIG. 1 is a schematic view showing a structure of a metal powder manufacturing apparatus according to an exemplary embodiment of the present invention;
FIG. 2 shows a schematic view of a decomposition process of a coarse-grained metal powder according to an exemplary embodiment of the present invention;
fig. 3 shows a schematic cross-sectional view of the coarse-grained metal powder as it begins to melt in an exemplary embodiment of the invention.
Reference numerals:
the device comprises a primary powder making device-100, a first atomizing chamber-110, a screening component-120, a secondary powder making device-200, a second atomizing chamber-210, a heating component-220, a collecting component-230, a powder feeding component-300, a vacuum system-400, an inert gas supply system-500, a high-pressure gas outlet end-510, a low-pressure gas outlet end-520, an inert gas source-530, a pressure control component-600, a metal bar-700, coarse-grain-size metal powder-800, a solid inner part-810, a liquid outer part-820 and fine-grain-size metal powder-900.
Detailed Description
Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments may, however, be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of example embodiments to those skilled in the art. The described features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
Furthermore, the drawings are merely schematic illustrations of embodiments of the invention, which are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and thus their repetitive description will be omitted. Some of the block diagrams shown in the figures are functional entities and do not necessarily correspond to physically or logically separate entities.
A metal powder manufacturing apparatus is provided in the present example embodiment. Referring to fig. 1, the apparatus may include: a primary pulverizing apparatus 100, a secondary pulverizing apparatus 200, a powder feeding assembly 300, and an inert gas supply system 500. The primary powder making device 100 comprises a first atomizing chamber 110 and a screening component 120 for screening metal powder into metal powder 800 with a coarse particle size and metal powder 900 with a fine particle size according to a preset size, and is used for making metal bar stock into metal powder; the secondary powder making apparatus 200 includes a second atomizing chamber 210 and a heating unit 220 for decomposing the coarse-grained metal powder 800, the heating unit 220 being provided in a communication path between the powder feeding unit 300 and the second atomizing chamber 210 for heating the coarse-grained metal powder 800 to a state of starting melting before the coarse-grained metal powder 800 is decomposed; the powder feeding assembly 300 is respectively communicated with the first atomizing chamber 110 and the second atomizing chamber 210, and is used for conveying the sieved coarse-grained metal powder 800 to the second atomizing chamber 210; the inert gas supply system 500 is in communication with the first atomization chamber 110, the second atomization chamber 210, and the heating assembly 220, and the inert gas supply system 500 is configured to provide a protective atmosphere in the first atomization chamber 110 and the second atomization chamber 210 and decompose the coarse-grained metal powder 800 by blowing inert gas to the heated coarse-grained metal powder 800.
It should be understood that the first atomizing chamber 110 provides a closed chamber for a single pulverizing process, and provides a water-cooled ring for powder cooling and an inert protective atmosphere environment. In addition, the primary powder making device can make powder in various ways, and preferably, a rotary electrode powder making way can be adopted. Specifically, the electrode bar is driven to rotate at a high speed by the rotation driving unit, the plasma gun applies high-temperature heat to the front end face of the electrode bar to melt the electrode bar to form a liquid film, the liquid film is thrown out under the action of high-speed centrifugal force to form a liquid line, the liquid line is cooled in an inert atmosphere, and the liquid line is cooled under the action of surface tension to form spherical metal powder.
In addition, a screen assembly 120 is installed at a lower position inside the first atomization chamber 110, and the metal powder is screened by the screen assembly 120, so that the fine-grained metal powder 900 directly falls into the bottom of the first atomization chamber 110. Another portion of the coarse metal powder 800 passes through the powder feed assembly 300 into the second atomization chamber 210.
It should be further understood that, as shown in fig. 3, when the powder feeding assembly 300 conveys the coarse-size metal powder 800 to the inside of the second atomizing chamber 210, the coarse-size metal powder 800 is heated by the heating assembly 220 to be in a state of starting to be melted to form an outer portion 820 in a liquid state and an inner portion 810 in a solid state, and after entering the inside of the second atomizing chamber 210 in this state, the coarse-size metal powder 800 is impacted by the inert gas supplied by the inert gas supply system 500, and the decomposition of the coarse-size metal powder 800 is completed in the second atomizing chamber 210, so that 1 coarse-size metal powder is decomposed into a plurality of fine-size metal powders. Since the coarse-grained metal powder 800 is easily reacted with other active gases to destroy the metal powder after being heated to a state of starting to be melted, a protective atmosphere is provided during the heating and decomposition of the coarse-grained metal powder 800. The protective atmosphere refers to a non-oxidation and non-decarburization gas protective environment, and gases such as nitrogen or argon can be selected, so that in order to ensure the reliability of the protective atmosphere and improve the purity of the inert gas in the protective atmosphere, vacuumizing can be performed before the inert gas is injected, and then the inert gas is injected to improve the purity of the inert gas in the protective atmosphere.
Wherein, the first atomizing chamber 110 and the second atomizing chamber 210 have sealability, and the bottom of the first atomizing chamber 110 and the second atomizing chamber 210 is provided with a powder discharge port for discharging fine-grained metal powder. The heating unit 220 may be an induction coil, an ion arc, an electric arc, or an electron beam, and the heating unit 220 is not particularly limited as long as the heating temperature of the coarse-grained metal powder 800 can be controlled.
It should be understood that the powder feeding assembly 300 may be a stop valve, and by making the bottom of the first atomizing chamber 110 higher than the top of the second atomizing chamber 210, the powder feeding assembly 300 can transport the sieved coarse-grained metal powder 800 to the second atomizing chamber 210 by gravity, and the powder feeding speed of the coarse-grained metal powder 800 can be adjusted by controlling the size of the stop valve, so as to improve the efficiency and save the cost.
By the aid of the device, on one hand, the metal bar is continuously milled twice, so that the collection rate of fine-grain metal powder is improved; on the other hand, the method has the advantages of high sphericity, good fluidity and good compressibility of the metal powder, and has the characteristics of high efficiency, good quality and good batch consistency.
Next, each part of the above-described apparatus in the present exemplary embodiment will be described in more detail with reference to fig. 1 to 3.
In one embodiment, and as shown with reference to FIG. 1, screen assemblies 120 include screens having a 100 μm diameter. It will be appreciated that the screen diameter may be designed according to the size of the fine particle size metal powder required, and that 100 μm is preferred for the screen diameter since in practice metal powders below 100 μm are often used.
In one embodiment, referring to the illustration in fig. 1, the top of the second atomization chamber 210 is provided with a cylindrical interface, and the cylindrical interface is provided with a sandwich, and the heating assembly 220 is disposed in the sandwich of the cylindrical interface. It is to be understood that the delivery end of the powder feeding assembly 300 may communicate with the second atomizing chamber 210 through a cylindrical interface, the heating assembly 220 may comprise a cylindrical interface, that is, the heating assembly 220 may comprise a cylindrical base provided with a sandwich and a heating element disposed in the sandwich, and the heating assembly 220 is mounted on the top of the second atomizing chamber 210. The heating element may be a constant induction coil, ion arc, electric arc or electron beam. In addition, because the heating assembly 220 is arranged at the top of the second atomizing chamber 210, after the coarse-grain-size metal powder 800 is conveyed to the top of the second atomizing chamber 210, the coarse-grain-size metal powder 800 can be directly heated in the second atomizing chamber 210, so that the heating and decomposition of the coarse-grain-size metal powder 800 can be completed in the atomizing chamber, the protective atmosphere for the coarse-grain-size metal powder 800 is more favorably provided, the atomizing chamber only needs to be kept in sealing performance, and the simplicity of the device is improved.
In one embodiment, referring to fig. 1, the inert gas supply system 500 comprises an inert gas source 530, a low pressure gas outlet end 520 and a high pressure gas outlet end 510, wherein the inert gas source 530 is used for supplying inert gas to the low pressure gas outlet end 520 and the high pressure gas outlet end 510, the low pressure gas outlet end is respectively communicated with the first atomization chamber 110 and the second atomization chamber 210, the high pressure gas outlet end is communicated with the second atomization chamber 210, and the high pressure gas outlet end 510 is disposed below the heating assembly 220. Referring to fig. 1, preferably, a low pressure gas outlet 520 provides a low pressure inert protective atmosphere through a pressure control valve B and a pressure control valve C, and a high pressure gas outlet 510 is disposed below the heating assembly 220 and provides a high pressure and high speed inert gas through a pressure control valve a, thereby decomposing the heated coarse-grained metal powder 800. The high-pressure air outlet end 510 may adopt a circular seam structure, or may adopt a coupling structure of a plurality of high-pressure nozzles, but is not limited specifically. In addition, the inert gas source 530 may be connected to the low-pressure gas outlet end 520 and the high-pressure gas outlet end 510 through one gas transmission channel, or may be connected to the low-pressure gas outlet end 520 and the high-pressure gas outlet end 510 through two independent gas transmission channels.
In one embodiment, referring to FIG. 2, the heating assembly 220 has a height ranging from 10 to 200mm, a diameter ranging from 2 to 100mm, and a power ranging from 1 to 1000 kW. Specifically, the height H = 10-200 mm and the diameter D = phi 2-100 mm of a heating area of the heating assembly 220; the heating element 220 may be a resistive heating, laser, or radio frequency inductively coupled plasma; the diameter of the coarse-grained metal powder 800 is varied from 100 to 200 μm depending on the melting point of the metal powder (e.g., from an aluminum alloy (600 ℃) to a tungsten alloy (3400 ℃)), and the power range of the corresponding heating unit 220 is 1 to 1000 kW.
Specifically, in one embodiment, as illustrated with reference to fig. 2 and 3, the height H, diameter D, and operating power of the heating assembly are related to the material and particle size of the coarse-grained metal powder 800. When the diameter is phi D1When the coarse-grained metal powder 800 is heated to a state where it starts to melt, the diameter of the solid inner portion 810 is Φ D2The outer portion 820 in the liquid state is in the range Φ D1-ΦD2The heat quantity Q required for the coarse-grained metal powder 800 to be heated to the state where melting starts is expressed by the correlation expression:
Figure DEST_PATH_IMAGE002
expression (1);
where ρ is the theoretical density of the metal powder, CPIs the specific heat, T, of the metal powdermIs the melting point of the metal powder, HmIs the latent heat of fusion, T, of the metal powder0Is at room temperature.
According to the expression, the heat quantity required for melting the single metal powder particle is in a cubic relation with the diameter, and the larger the particle size of the powder particle is, the larger the energy required for melting is, and the powder particle is not easy to evaporate. The metal powder heated by the heating assembly 220 generally undergoes the following stages: solid phase heating, heating from an initial temperature to the melting point of the material, and melting the solid phase at the melting point; the liquid phase is heated from the melting point of the material to near the boiling point of the material. The heat quantity of the coarse-grained metal powder 800 required by each stage in the heating element 220 is calculated, and the working power of the heating element 220 is adjusted accordingly.
In one embodiment, the powder feeding speed of the powder feeding assembly 300 is in a range of 10-10000 g/min, and the powder feeding speed of the powder feeding assembly 300 is related to the working power of the heating assembly 220. It is to be understood that the amount of heat required to heat a single metal powder can be derived from expression (1), and the amount of metal powder to be heated by the heating assembly 220, and thus the operating power of the heating assembly 220, can be determined by adjusting the powder feeding speed of the powder feeding assembly 300.
In one embodiment, referring to the illustration in fig. 1, the apparatus further comprises a vacuum system 400, the vacuum system 400 being in communication with the first nebulizing chamber 110 and the second nebulizing chamber 210 for providing a vacuum environment prior to the inert gas supply system 500 providing the protective atmosphere. After the vacuum pumping, extra gas can be effectively removed, and then the inert gas supply system 500 is used for providing inert gas for the first atomizing chamber 110 and the second atomizing chamber 210, so that the purity of the inert gas in the first atomizing chamber 110 and the second atomizing chamber 210 can be improved, and the reliability of the protective atmosphere is ensured.
In one embodiment, referring to fig. 1, the apparatus further comprises a pressure control assembly 600, the pressure control assembly 600 being in communication with the second nebulizing chamber 210 for stabilizing the pressure inside the second nebulizing chamber 210. When the inert gas supply system 500 blows the inert gas for decomposing the coarse-grained metal powder 800, since the excessive inert gas raises the internal pressure of the second atomizing chamber 210, thereby affecting the blowing speed of the inert gas and further affecting the effective decomposition of the coarse-grained metal powder 800, the excessive gas is discharged through the pressure control assembly 600, the internal pressure of the second atomizing chamber 210 is stabilized, and thus the efficient operation of the apparatus is ensured.
In one embodiment, referring to fig. 1, the apparatus further comprises a collection assembly 230, the collection assembly 230 communicating with the bottom of the first atomization chamber 110 and the second atomization chamber 210 for collecting fine particle size metal powder 900. Wherein the collection assembly 230 simultaneously ensures the sealing performance of the first atomization chamber 110 and the second atomization chamber 210 during the process of collecting the metal powder, so that the device continuously operates while collecting the metal powder. It should be understood that the collection assembly 230 may be fixedly connected to the first atomization chamber 110 and the second atomization chamber 210, and the collected metal powder may be stored in an additional container. The collection assembly 230 may be detachably connected to the first atomization chamber 110 and the second atomization chamber 210, and when the collection assembly finishes collecting the metal powder, the collection assembly may be detached, replaced with another collection assembly, and the metal powder may be continuously collected. Preferably, the collection assembly 230 includes a pneumatic butterfly valve for maintaining the sealability of the first and second atomization chambers 110 and 210 during the collection of the metal powder, and a powder collection tank for storing the refined metal powder.
A method of manufacturing a metal powder is also provided in this example embodiment. Referring to fig. 1 to 3, the method may include the steps of:
providing a protective atmosphere through the inert gas supply system 500;
in a protective atmosphere, making metal bar materials into metal powder by a primary powder making device 100;
sieving the metal powder into coarse-sized metal powder 800 and fine-sized metal powder 900 by the sieving assembly 120;
transporting the coarse-grained metal powder 800 to the second atomization chamber 210 by the powder feed assembly 300;
heating the coarse-grained metal powder 800 to a state of starting to melt before the coarse-grained metal powder 800 is decomposed by the heating assembly 220 in a protective atmosphere;
in the protective atmosphere, the inert gas supply system 500 blows the inert gas to the heated coarse-particle-size metal powder 800 to decompose the coarse-particle-size metal powder 800.
The coarse-grained metal powder 800 in a state of starting to melt has an outer portion 820 in a liquid state and an inner portion 810 in a solid state.
It is to be understood that, when the powder feeding assembly 220 conveys the coarse-size metal powder 800 to the inside of the second atomizing chamber 210, the coarse-size metal powder 800 is heated by the heating assembly 220 to be in a state of starting to be melted to form an outer part 820 in a liquid state and an inner part 810 in a solid state, and after the coarse-size metal powder 800 enters the inside of the second atomizing chamber 210 in this state, the coarse-size metal powder 800 is impacted by the inert gas supplied by the inert gas supply system 500, and the decomposition of the coarse-size metal powder 800 is completed in the second atomizing chamber 210, so that 1 coarse-size metal powder is decomposed into a plurality of fine-size metal powders. The powder feeding assembly 300 may supply a fixed amount of the coarse-grained metal powder 800 to the heating assembly 220 and the second atomizing chamber 210 by uniform transportation. Thereby stabilizing the heating and decomposition process of the coarse-grained metal powder 800. Meanwhile, the inert gas supply system 500 fills inert gas with purity greater than 99.999% into the first atomization chamber 110 and the second atomization chamber 210 to positive pressure of 0.02-0.2 Mpa, so as to satisfy the high-purity inert atmosphere environment of the atomization powder-making forming process.
It should also be understood that the first atomizing chamber 110 and the second atomizing chamber 210 generally have powder discharge openings, and therefore, after the powder production is completed, the fine-grained metal powder can also be discharged out of the first atomizing chamber 110 and the second atomizing chamber 210 through the powder discharge openings of the first atomizing chamber 110 and the second atomizing chamber 210.
In one embodiment, the coarse-grained metal powder 800 is heated by the heating assembly 220 to have an outer portion 820 that is in a liquid state and an inner portion 810 that is in a solid state. Preferably, the heating assembly 220 heats the coarse-grained metal powder 800 using gradient heating. The gradient heating method is to divide the heating area of the heating element 220 into different heating sections, each section has different heating temperatures, the heating temperature or the heat preservation time is precisely controlled in a segmented manner, and the heating temperatures of the sections are in an increasing relationship. However, the present invention is not limited to a specific heating method of the heating unit 220, and the coarse-grained metal powder 800 may be heated to a state where it starts to melt. In addition, the height and the energy of the heating area of the heating assembly can be respectively adjusted according to different metal powder materials and different particle sizes. Thereby allowing the coarse-grained metal powder 800 to be heated accurately and rapidly in a state of starting to melt.
In one embodiment, the heated coarse-grained metal powder 800 is separated from the solid inner portion 810 by blowing inert gas at a pressure of 3 to 8MPa and a velocity of 50 to 800m/s through the inert gas supply system 500. The pressure and velocity of the inert gas blown by the inert gas supply system 500 are adjusted to accommodate various types of coarse-grained metal powder.
In one embodiment, a vacuum environment is provided by the vacuum system 400 prior to the protective atmosphere being provided by the inert gas supply system 500. Since the coarse-grained metal powder 800 is easily reacted with other active gases to break the metal powder when it is heated to a state of starting melting, a protective atmosphere is provided during the heating and decomposition of the coarse-grained metal powder 800. The purity of the inert gas in the protective atmosphere can be improved by vacuumizing before the inert gas is injected and then injecting the inert gas. Specifically, the vacuum system 400 provides a vacuum environment in the atomizing chamber 100 to ensure that the ultimate vacuum degree reaches 5 × 10-3Pa。
In one embodiment, the powder feed speed of the powder feed assembly 300 and the operating power of the heating assembly are adjusted for different materials and particle sizes of the metal powder. Specifically, the powder feeding speed range can be 10-10000 g/min, and the power range of the heating assembly can be 1-1000 kW. Thereby making it possible to apply the present invention to various metal powders.
In one embodiment, the discharged fine particle size metal powder 900 is collected by the collection assembly 230 while maintaining the hermeticity of the first atomization chamber 110 and the second atomization chamber 210. Wherein the collecting assembly 230 simultaneously ensures the sealing performance of the first atomizing chamber 110 and the second atomizing chamber 210 during the process of collecting the metal powder, thereby allowing the device to continuously operate while collecting the metal powder.
There is also provided in this example embodiment a method of using a metal powder manufacturing apparatus, which may include the steps of:
step 1, vacuumizing the first atomization chamber 110 and the second atomization chamber 210 through a vacuum system 400 to ensure that the ultimate vacuum degree of the atomization chamber 100 reaches 5 x 10-3Pa；
Step 2, filling inert gas with the purity of more than 99.999 percent into the first atomizing chamber 110 and the second atomizing chamber 210 through the low-pressure gas outlet end 520 of the inert gas supply system 500 to reach the positive pressure of 0.02-0.2 Mpa, so as to meet the high-purity inert atmosphere environment of the atomized powder forming process;
step 3, starting the primary powder making device 100 to make the metal bar into the metal powder;
step 4, screening the metal powder into coarse-grain-size metal powder 800 and fine-grain-size metal powder 900 through the screening component 120, and collecting the fine-grain-size metal powder 900 through the collecting component 230;
step 5, starting the heating assembly 220, and generating a high-temperature heating area in the heating assembly 220, wherein the heating power range of the heating assembly 220 is 1-1000 kW;
step 6, conveying a fixed amount of coarse-grain-size metal powder raw material 800 to a heating area of the heating assembly 220 at a fixed speed through the powder feeding assembly 300, wherein the powder feeding speed range is 10-10000 g/min according to different materials of the metal powder raw material and the melting speed of the external part, and the temperature field distribution of the heating assembly 220 is adjusted according to different metal powder materials and different grain sizes;
step 7, under the action of the heating assembly 220, realizing a state that the coarse-grain-size metal powder 800 starts to melt, and forming an external part 820 in a liquid state and an internal part 810 in a solid state; by contacting with the high-speed high-pressure inert gas, the solid inner part 810 is decomposed to form individual metal powder under the action of the high-speed high-pressure gas, and the liquid outer part 820 is further crushed under the action of the inert gas, so that the initial 1 piece of coarse-grain-size metal powder is finally decomposed into a plurality of pieces of fine-grain-size metal powder.
This portion of fine particle size metal powder is collected by collection assembly 230, step 8.
Exemplary, methods of making TC4 metal powder by plasma rotating electrode method. The method comprises the following specific steps:
step 1, vacuumizing the atomization chamber 100 through a vacuum system 400 to ensure that the ultimate vacuum degree of the first atomization chamber 110 and the second atomization chamber 210 reaches 5 × 10-3Pa；
Step 2, filling inert gas with the purity of more than 99.999 percent into the first atomizing chamber 110 and the second atomizing chamber 210 through the low-pressure gas outlet end 520 of the inert gas supply system 500 to reach the positive pressure of 0.02-0.2 Mpa, so as to meet the high-purity inert atmosphere environment of the atomized powder forming process;
and 3, starting a rotation driving unit of the primary powder preparation device 100, driving the electrode bar with the diameter of 50mm to rotate at a high speed, applying high-temperature heat to the front end surface of the electrode bar by a plasma gun to melt the electrode bar to form a liquid film, throwing the liquid film out under the action of high-speed centrifugal force to form a liquid line, cooling the liquid line in an inert atmosphere, and cooling under the action of surface tension to form spherical metal powder. The particle size range of the TC4 powder prepared by the technology is 15-200 mu m;
step 4, the TC4 spherical metal powder falls onto the screening assembly 120 under the action of gravity, and the spherical metal powder is screened by the screening assembly 120, wherein the diameter of the screen is 100 mu m; the fine-grained metal powder having a grain size of less than 100 μm directly falls into the bottom of the first atomization chamber 110, and is collected by the collection assembly 230. The coarse-grain-size metal powder 800 with the grain size larger than 100 mu m enters the secondary powder making device 200 through a stop valve;
step 3, starting the heating assembly 220, and enabling a high-temperature heating area to be generated inside the heating assembly 220 in a resistance heating mode, wherein the heating power of the heating assembly 220 is 20kW, the height H =50mm of the heating area, and the diameter D = phi 10 mm;
step 4, conveying a fixed amount of coarse-grain-size metal powder raw material 800 to a heating area of the heating assembly 220 at a fixed speed through a stop valve, wherein the powder conveying speed is 10g/min and the corresponding heating time is 0.5S according to the melting speed of the metal powder, and the temperature field distribution of the heating assembly 220 is adjusted to enable the temperature of the metal powder to reach 2000 ℃;
step 5, under the action of the heating assembly 220, realizing the state that the coarse-grain-size metal powder 800 starts to melt, and forming a liquid external part 820 and a solid internal part 810, taking the metal powder with the grain size of 200 μm as an example, the diameter range of the liquid external part 820 is 80-200 μm, and the diameter of the solid internal part 810 is 80 μm due to short heating time, at this time, under the action of gravity, the metal powder in the melting starting state falls and is separated from the heating assembly 220, and enters a high-speed inert gas action area;
step 6, adjusting a high-pressure gas outlet end 510 of the inert gas supply system 500, wherein the pressure of the output inert gas is 3Mpa, and the speed is 100 m/s; under the action of the high-speed high-pressure gas, the solid inner part 810 is decomposed to form individual metal powder, and the liquid outer part 820 is further crushed under the action of the inert gas, so that the initial 1 piece of coarse-grain-size metal powder is finally decomposed into a plurality of pieces of fine-grain-size metal powder.
And 7, collecting the fine-grained metal powder through the collecting assembly 230.
It is to be understood that the terms "central," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," and the like in the foregoing description are used for indicating or indicating the orientation or positional relationship illustrated in the drawings, and are used merely for convenience in describing embodiments of the present invention and for simplifying the description, and do not indicate or imply that the device or element so referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore should not be construed as limiting the embodiments of the present invention.
Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of the present invention, "a plurality" means two or more unless specifically limited otherwise.
In the embodiments of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," "fixed," and the like are to be construed broadly, e.g., as being fixedly connected, detachably connected, or integrated; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood by those skilled in the art according to specific situations.
In embodiments of the invention, unless expressly stated or limited otherwise, the first feature "on" or "under" the second feature may comprise the first and second features being in direct contact, or the first and second features being in contact, not directly, but via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples described in this specification can be combined and combined by those skilled in the art.
Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. This application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Claims (10)

1. A metal powder manufacturing apparatus, characterized by comprising:
the primary powder making device is used for making metal bars into metal powder and comprises a first atomizing chamber and a screening component for screening the metal powder into metal powder with a coarse particle size and metal powder with a fine particle size according to a preset size;
the secondary powder making device comprises a second atomizing chamber and a heating component and is used for decomposing the coarse-grain-size metal powder;
the powder feeding assembly is respectively communicated with the first atomizing chamber and the second atomizing chamber and is used for conveying the sieved metal powder with the coarse particle size to the second atomizing chamber; and
an inert gas supply system in communication with the first atomization chamber, the second atomization chamber, and the heating assembly, the inert gas supply system configured to provide a protective atmosphere in the first atomization chamber and the second atomization chamber and to decompose the heated coarse-grained metal powder by blowing an inert gas thereto;
wherein the heating unit is provided in a communication path between the powder feeding unit and the second atomizing chamber, and heats the coarse-grained metal powder to a state where the coarse-grained metal powder starts to melt before the coarse-grained metal powder is decomposed.
2. The apparatus of claim 1, wherein the screen assembly comprises a screen having a diameter of 100 μm.
3. The apparatus of claim 1, wherein the top of the second atomization chamber is provided with a cylindrical port, the cylindrical port is provided with a sandwich, and the heating assembly is disposed in the sandwich of the cylindrical port.
4. The apparatus of claim 1, wherein the inert gas supply system comprises an inert gas source, a low pressure gas outlet end and a high pressure gas outlet end, the inert gas source is configured to supply inert gas to the low pressure gas outlet end and the high pressure gas outlet end, the low pressure gas outlet end is respectively communicated with the first atomization chamber and the second atomization chamber, the high pressure gas outlet end is communicated with the second atomization chamber, and the high pressure gas outlet end is disposed below the heating assembly.
5. The apparatus of claim 3, wherein the heating assembly has a height ranging from 10 to 200mm, a diameter ranging from 2 to 100mm, and a power ranging from 1 to 1000 kW.
6. The apparatus of claim 3, wherein the height, diameter and operating power of the heating assembly are related to the material and particle size of the coarse-grained metal powder.
7. The apparatus of any one of claims 1-6, wherein the powder feeding assembly has a powder feeding speed in a range of 10 to 10000g/min, the powder feeding speed of the powder feeding assembly being related to the operating power of the heating assembly.
8. A method of manufacturing metal powder using the apparatus of any one of claims 1 to 7, comprising:
providing a protective atmosphere through the inert gas supply system;
in the protective atmosphere, preparing metal bar stock into the metal powder by the primary powder preparing device;
sieving the metal powder into a coarse-size metal powder and a fine-size metal powder by the sieve assembly;
conveying the coarse-grained metal powder to the second atomization chamber through the powder feeding assembly;
heating, by the heating assembly, the coarse-grained metal powder to a state that begins to melt before the coarse-grained metal powder is decomposed in the protective atmosphere;
blowing an inert gas to the heated coarse-particle-size metal powder by the inert gas supply system in the protective atmosphere to decompose the coarse-particle-size metal powder;
wherein the coarse-grained metal powder in a state of starting to melt has an outer portion in a liquid state and an inner portion in a solid state.
9. The method according to claim 8, wherein the outer part in the liquid state is separated from the inner part in the solid state by blowing an inert gas having a pressure of 3 to 8Mpa and a velocity of 50 to 800m/s to the heated coarse-grained metal powder by an inert gas supply system.
10. Method according to any of claims 8 or 9, characterized in that the powder feeding speed of the powder feeding assembly and the operating power of the heating assembly are adjusted for different materials and particle sizes of the metal powder.
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