TW201714685A - Spherical metal powder and manufacturing method thereof and manufacturing apparatus thereof capable of allowing the fine metal particles to converge into a spherical shape in a relatively long time to achieve the purpose of improving the metal powder roundness - Google Patents

Abstract

The present invention mainly uses the heat energy produced by arc discharge to heat and melt at least one metal material fed into the arc discharge region to form a liquid metal, and the gas flow having a predetermined kinetic energy is applied to the arc discharge region to immediately give first atomization to the molten liquid metal of metal material to form a plurality of fine metal droplets. At the same time, at least one plasma jet is applied to the metal droplets produced by the first atomization to make them atomize again into a plurality of fine metal particles. It can not only effectively reduce the heat loss of the metal droplets, but also provide sufficient temperature by the plasma jet to allow the fine metal particles to converge into a spherical shape in a relatively long time, achieving the purpose of improving the metal powder roundness.

Description

Spherical metal powder, manufacturing method thereof and manufacturing equipment thereof

The present invention relates to a metal powder manufacturing technique, and mainly discloses a spherical metal powder having a relatively good circular ratio, and a method for producing a spherical powder and a spherical spherical powder manufacturing apparatus therefor.

In recent years, with the development of metal injection molding, metal thermal spraying, metal rapid prototyping, metal laminate manufacturing (3D printing) and other technologies, the application of metal powder in electronics, information, metallurgy, energy, aerospace and other fields Increasingly, the performance requirements for the fineness, purity, and morphology of metal powders are gradually increasing.

Furthermore, the appearance of the metal particles in the metal powder has an important influence on the subsequent application of the finished product; for example, the roundness of the tin powder is increased, the printability is improved after the solder paste is formed, and the metal layer is laminated. When manufacturing (3D printing) metal powder, if the roundness of the metal powder is increased, the mobility of the metal powder can be increased, thereby improving the flatness of the metal powder after tiling.

According to the J-STD-005 (solder paste requirements) standard officially published by the International Electronics Industry Association (IPC), spherical powder has two requirements; one is more than 90% of the particles, and the maximum ratio of the longest axis to the shortest axis 1.5, if the ratio is greater than 1.5, it is judged to be a non-spherical powder; the second is 90% or more of particles, and the roundness is between 1 and 1.07 (round circle is 1 is a perfect circle), if greater than 1.07 It was judged to be a non-spherical powder.

As for the measurement method of the ratio of the longest axis to the shortest axis of the metal powder and the roundness, the metal particles in the metal powder are sent to a scanning electron microscope for observation, and then the output of the observed image is analyzed by software for image calculation. The longest axis length, the shortest axis length, the circumference length and the area of each metal particle obtained are then nested into the formula to calculate the ratio of the longest axis to the shortest axis and the circular ratio.

Among the many metal powder manufacturing methods, the gas atomization method should be regarded as the mainstream of the current metal powder preparation technology. The gas atomization method is used to produce metal or alloy powder, mainly by using high-speed gas flow to refine the metal droplets and make it Solidification into powder particles; in the current technology of preparing metal powder by gas atomization method, the multi-system first heats the solid metal material into a liquid state, and then introduces it into a droplet type The sonic flow acts in the atomization chamber.

Since the molten liquid metal exhibits a droplet type, most of the heat energy has been lost. Therefore, during the solidification process after the metal droplet is refined, relatively insufficient temperature and time are allowed to converge into a spherical shape. The metal powder formed by it generally has a phenomenon in which a small number of spherical metal particles and a plurality of elliptical metal particles are uneven in particle size.

However, at present, the technical improvement of the preparation of metal powder by gas atomization method is still focused on how to improve the atomization efficiency of metal powder, and it is generally believed that the structural design of controlling the ultrasonic gas jet nozzle becomes the key technology of metal powder atomization. As for the technology on how to increase the roundness of metal powder, it is rarely revealed.

In view of the above, the present invention is to disclose a spherical metal powder having a relatively good circular ratio, and a method for producing a spherical powder and a spherical spherical powder manufacturing apparatus therefor, which are the main objects thereof.

In order to achieve the above object, the method for manufacturing a spherical powder disclosed in the present invention utilizes thermal energy of arc discharge to heat-melt at least one metal material fed into an arc discharge region to form a molten metal, and is acted upon by a gas stream having a predetermined kinetic energy. In the arc discharge region, the molten metal melted by the at least one metal material is immediately subjected to a first atomization to form a plurality of fine metal droplets, and at the same time, at least one plasma jet is applied to the first atomization chamber. The formed metal droplets are atomized again into a plurality of fine metal particles, and the preparation of the spherical metal powder is completed after the cooling and shaping of all the fine metal particles.

According to the above technical feature, the method for manufacturing a spherical powder disclosed in the present invention mainly applies a first atomization to form a plurality of metal droplets at a moment when the metal raw material is melted into a molten metal to reduce the thermal energy of the metal droplets. Loss, followed by a second atomization of the metal droplets by the plasma jet to form a plurality of fine metal particles, and the plasma jet provides sufficient temperature to allow the fine metal particles to converge into a spherical shape for a relatively long period of time. To achieve the purpose of increasing the roundness of metal powder.

According to the above technical feature, the method for manufacturing a spherical powder is to perform arc discharge, first atomization, and second atomization in a closed chamber.

According to the above technical feature, the method for producing a spherical powder is to use the at least one metal material as an electrode for performing arc discharge.

According to the above technical feature, the method for manufacturing a spherical powder is to use the at least one metal material as an electrode for performing arc discharge, and performing arc discharge, first atomization, and second atomization in a closed chamber. .

The at least one metal raw material may be one of titanium, tin, copper, zinc, aluminum, gold, silver, iron, nickel or an alloy thereof.

The at least one metal raw material is a wire metal raw material having a predetermined wire diameter.

The at least one metal raw material is a rod metal raw material having a predetermined wire diameter.

The gas stream acting on the arc discharge region may be one of air, oxygen, nitrogen, argon, helium, hydrogen, carbon monoxide, carbon dioxide, or a combination thereof.

The operating temperature of the arc discharge zone is between 1000 ° C and 6000 ° C.

The operating temperature of the at least one plasma jet is between 1000 ° C and 10000 ° C.

The average particle diameter of the metal droplets is between 100 and 500 μm.

The fine metal particles have an average particle diameter of less than 100 μm.

The method for manufacturing the spherical powder is to use two copper wire metal materials having a diameter of 1.6 mm as an electrode for generating an arc discharge, and to pass under vacuum after the chamber is evacuated to <1×10 ⁻³ Pa. 0.12~0.15MPa of nitrogen gas is used to generate two arc wires of 1.6mm copper wire metal material by arc current, and two copper wire metal materials with a diameter of 1.6mm are heated and dissolved to produce metal liquid, and the inlet pressure is 0.5. MPa is fed with nitrogen to form a gas flow acting on the arc discharge region, and two copper metal materials having a diameter of 1.6 mm are thermally melted and subjected to a first atomization to form a plurality of fine copper metal droplets, followed by The three groups of power are each 25kW, and the plasma jet generated by the plasma torch with the inlet pressure of 0.5MPa acts on the copper metal droplet formed by the first atomization, causing it to be atomized again into a plurality of fine copper metal. Particles.

The method for manufacturing the spherical powder is to use two titanium wire metal materials having a diameter of 1.6 mm as an electrode for generating an arc discharge, and the inlet is lower than after the chamber is evacuated to <1×10 ^-3 Pa. 0.12~0.15MPa of nitrogen gas, through the current of 150A, two 1.6mm diameter titanium wire metal materials are arc-discharged, and two 1.6mm diameter titanium wire metal materials are heated and dissolved to produce molten metal, and the inlet pressure is 0.5. MPa is fed with argon to form a gas flow acting on the arc discharge region, and two metal liquids of 1.6 mm diameter of the titanium wire metal material are subjected to a first atomization to form a plurality of fine titanium metal droplets, followed by The three groups of power are each 25kW, and the plasma jet generated by the plasma torch with an inlet pressure of 0.5MPa acts on the titanium metal droplet formed by the first atomization, causing it to be atomized again into a plurality of fine titanium metal. Particles.

The method for manufacturing the spherical powder is to use two tin alloy wire metal materials with a diameter of 2.0 mm as an electrode for generating an arc discharge, and to pass the vacuum to the chamber after <1×10 ^-3 Pa. The nitrogen gas of 0.12~0.15MPa is used to generate arc discharge of the two tin alloy wire metal materials by the current of 110A, and the two tin alloy wire metal materials are heated and dissolved to produce the metal liquid, and the nitrogen gas is formed by the inlet pressure of 0.3 MPa. The gas flow acting on the arc discharge region applies the tin alloy metal liquid which is thermally melted to the two tin alloy wire metal materials to the first atomization to form a plurality of fine tin alloy metal droplets, and then each of the three sets of power is 20 kW. The plasma jet generated by the plasma torch with an inlet pressure of 0.4 MPa acts on the tin alloy metal droplet formed by the first atomization, and is atomized again into a plurality of fine tin alloy metal particles.

The tin alloy wire metal raw material is a tin-silver-copper alloy wire.

The apparatus for manufacturing a spherical metal powder disclosed in the present invention is provided in a chamber: an arc heating unit, a first atomizing unit, and a second atomizing unit; wherein: the arc heating unit is for connection And an anode for generating an arc discharge, and for receiving at least one metal material as an electrode for generating an arc discharge, and generating an arc for heating and dissolving the at least one metal material into a molten metal after the electrode is energized; The atomization unit is configured to apply a gas stream having a predetermined kinetic energy to an arc discharge region of the arc heating unit, and apply a first atomization to the metal liquid heated and melted by the at least one metal material to form a plurality of metal droplets; The second atomization unit is a metal droplet formed by the first atomization of the first atomization unit by a plasma jet, so that the metal droplet formed by the first atomization is atomized again into a plurality of fine particles. Metal particles.

According to the above structural features, the arc heating unit is provided with two sets of electrodes for respectively connecting positive and negative charges, and two sets of brackets for guiding the electric charges connected to the electrodes into the arc discharge area.

According to the above structural feature, the first atomizing unit is provided with at least one set of nozzles for applying a gas stream having a predetermined kinetic energy to the arc discharge region.

According to the above structural feature, the second atomizing unit is provided with at least one plasma torch for generating a plasma jet after energization, and the at least one plasma torch is set to cause the plasma jet generated by the plasma atomizing device to act on The gas flow of the first atomizing unit passes through the stroke after the arc discharge region.

According to the above structural feature, the arc heating unit is provided with two sets of electrodes for respectively connecting positive and negative charges, and two sets of brackets for guiding the electric charges connected to the electrodes into the arc discharge area; The atomizing unit is provided with at least one set of nozzles for applying a predetermined kinetic energy to the arc discharge area; the second atomizing unit is provided with at least one plasma torch for generating a plasma jet after being energized, At least one of the plasma torches is configured such that the plasma jet produced thereby acts on the stroke of the first atomizing unit after the gas stream passes through the arcing region.

The spherical metal powder manufacturing apparatus further includes a feeding unit for receiving at least one metal material and advancing the metal material to be taken toward the arc discharge region.

The spherical metal powder manufacturing apparatus further includes a feeding unit capable of receiving at least one metal raw material and advancing the metal raw material received toward the arc discharge area; each of the brackets of the arc heating unit is provided with a The passage for the metal raw material to pass through; the feeding unit is respectively provided with at least two transfer wheels for contacting the metal raw materials corresponding to the respective brackets.

The spherical metal powder manufacturing apparatus further includes a feeding unit capable of receiving at least one metal raw material and advancing the metal raw material received toward the arc discharge region; the arc heating unit is disposed in one of the brackets There is a passage for the metal material to pass through; the feeding unit is provided with at least two transfer wheels for contacting the metal material corresponding to the bracket provided with the passage.

At least one nozzle of the first atomizing unit is disposed between the two sets of brackets of the arc heating unit.

At least one nozzle of the first atomizing unit is disposed at a periphery of two sets of brackets of the arc heating unit.

At least one plasma torch of the second atomizing unit is disposed at a periphery of two sets of brackets of the arc heating unit.

The spherical metal powder disclosed in the present invention is a spherical metal powder which is manufactured according to various possible methods for producing a spherical powder, and the spherical metal powder has a plurality of fine metal particles, and all of the fine metal particles thereof The average particle diameter is less than 100 μm, and 92% or more of the fine metal particles have a circular ratio of 1 to 1.07, and 92% or more of the fine metal particles have a ratio of the longest axis to the shortest axis of less than 1.5.

The spherical metal powder disclosed in the present invention is a spherical metal powder which is manufactured according to various possible spherical spherical powder manufacturing apparatuses, and the spherical metal powder has a plurality of fine metal particles, and all of the fine metal particles thereof The average particle diameter is less than 100 μm, and 92% or more of the fine metal particles have a circular ratio of 1 to 1.07, and 92% or more of the fine metal particles have a ratio of the longest axis to the shortest axis of less than 1.5.

The spherical metal powder has a plurality of fine copper metal particles, and the average particle diameter of all the fine copper metal particles is between 30 and 50 μm, and more than 96% of the fine copper metal particles have a circularity of less than 1.5, and More than 95% of the fine copper metal particles have a roundness between 1 and 1.07.

The spherical metal powder has a plurality of fine titanium metal particles, and the average particle diameter of all the fine titanium metal particles is between 15 and 30 μm, and more than 97% of the fine titanium metal particles have a circularity of less than 1.5, and More than 94% of the fine titanium metal particles have a roundness between 1 and 1.07.

The spherical metal powder has a plurality of fine tin alloy metal particles, and the average particle diameter of all the fine tin alloy metal particles is between 25 and 45 μm, and more than 95% of the fine tin alloy metal particles have a circularity of less than 1.5. And more than 92% of the fine tin alloy metal particles have a roundness between 1 and 1.07.

The above fine tin alloy metal particles are tin-silver-copper alloy metal particles.

Since the present invention mainly applies a first atomization of a metal material to a molten metal to form a plurality of metal droplets, and then applies a plasma jet to the metal droplet for a second time. Atomization to form a plurality of fine metal particles can not only effectively reduce the thermal energy loss of the metal droplets, but also provide sufficient temperature by the plasma jet to allow the fine metal particles to converge into a spherical shape for a relatively long period of time, thereby increasing the roundness of the metal powder. The purpose; in particular, the metal liquid melted by the arc heating can effectively increase the distribution rate of the fine metal particles after the first atomization and the second atomization, and the circle is relatively more positive and reliable. The production capacity and quality of spherical metal powder.

The method for manufacturing a spherical powder disclosed in the present invention is to use a thermal energy of arc discharge to heat and melt at least one metal material fed into an arc discharge region to form a molten metal, and a gas stream having a predetermined kinetic energy acts on the arc discharge region, The molten metal melted by the at least one metal material is immediately subjected to a first atomization to form a plurality of fine metal droplets, and at the same time, at least one plasma jet is applied to the metal droplets formed by the first atomization. Then, it is atomized again into a plurality of fine metal particles, and the entire micro-fine metal particles are cooled and shaped to complete the manufacturing process of the spherical metal powder 10A having a plurality of fine metal particles as shown in FIG.

Specifically, the method for manufacturing a spherical powder disclosed in the present invention mainly applies a first atomization to form a plurality of metal droplets at a moment when the metal raw material is thermally melted into a molten metal to reduce thermal energy loss of the metal droplets. The average particle size of all the metal droplets may be between 100 and 500 μm, and then the second atomization of the metal droplets by the plasma jet forms a plurality of fine metal particles, and the average particles of all the fine metal particles The diameter system can be less than 100 μm, and the plasma jet provides sufficient temperature to allow the fine metal particles to converge into a spherical shape for a relatively long period of time, thereby achieving the purpose of increasing the roundness of the metal powder.

The method for manufacturing the spherical powder of the present invention can be subjected to arc discharge, first atomization and second atomization in a closed chamber, and the working temperature of the arc discharge region can be 1000. Between °C and 6000 °C; the operating temperature of at least one of the plasma jets may be between 1000 ° C and 10000 ° C.

The method for manufacturing the spherical powder of the present invention can be directly used as the electrode for performing arc discharge directly by using the at least one metal raw material; of course, the method for manufacturing the spherical powder of the present invention directly uses the at least one metal raw material. In order to perform the arc discharge electrode, it is preferable to perform arc discharge, first atomization, and second atomization in a closed chamber 20.

Furthermore, in the method for producing a spherical powder of the present invention, at least one metal raw material used may be one of titanium, tin, copper, zinc, aluminum, gold, silver, iron, nickel or an alloy thereof; The at least one metal material is a wire metal material having a predetermined wire diameter, or a bar metal material having a predetermined wire diameter; and the gas flow acting on the arc discharge region may be air, oxygen, nitrogen, or argon. One of gas, helium, hydrogen, carbon monoxide, carbon dioxide, or a combination thereof.

As shown in FIG. 2 and FIG. 3, the apparatus for manufacturing a spherical metal powder disclosed in the present invention is basically provided with a arc heating unit 30, a first atomizing unit 40, and a chamber 20, and a second atomizing unit 50; wherein:

The arc heating unit 30 is configured to connect positive and negative charges for generating an arc discharge, and is configured to receive at least one metal material 10 as an electrode for generating an arc discharge, and the at least one metal material is heated after the electrode is energized. The arc is dissolved into a molten metal; in practice, the arc heating unit 30 may be provided with two sets of electrodes 31 and 32 for respectively connecting positive and negative charges, and two sets of electric charges for connecting the electrodes. The holder 33 leading into the arc discharge region 30A is guided; in the embodiments shown in Figs. 2 and 3, each of the brackets 33 of the arc heating unit 30 is further provided with a passage 331 through which the metal material 10 can pass.

The first atomizing unit 40 is configured to apply a gas stream having a predetermined kinetic energy to an arc discharge region of the arc heating unit 30, and apply a first atomization to the molten metal of the at least one metal material 10 to be thermally fused. In the implementation, the first atomizing unit 40 may be provided with at least one set of nozzles 41 for applying a predetermined kinetic energy to the arc discharge region 30A, and the at least one nozzle system may be disposed at the nozzle The two sets of brackets of the arc heating unit, or as shown, are disposed between the two sets of brackets 33 of the arc heating unit 30.

The second atomizing unit 50 is a metal droplet 11 formed by the first atomization of the first atomizing unit 40 by a plasma jet, so that the metal droplet 11 formed by the first atomization is formed. Re-igniting into a plurality of fine metal particles 12; in practice, the second atomizing unit 50 may be provided with at least one plasma torch 51 for generating a plasma jet after energization, the at least one plasma torch 51 The plasma jet generated is configured to act on the stroke of the first atomizing unit 40 after the airflow passes through the arc discharge region 30A; in the embodiment, the at least one plasma torch 51 is disposed in the arc The two sets of brackets 33 of the heating unit 40 are peripheral.

Of course, the spherical metal powder manufacturing apparatus disclosed in the present invention is implemented by the arc heating unit 30, and two sets of electrodes 31 and 32 for respectively connecting positive and negative charges may be provided, and another The two groups direct the charge connected to each electrode into the holder 33 of the arc discharge area 30A; the first atomization unit 40 may be provided with at least one set of nozzles 41 for applying a predetermined kinetic energy to the arc discharge area 30A; And the second atomizing unit 50 may be provided with at least one plasma torch 51 for generating a plasma jet after being energized, and the at least one plasma torch 51 is set to cause the plasma jet generated by the plasma atomizing nozzle Preferably, the gas flow of the first atomizing unit 40 passes through the structural form at the stroke after the arc discharge region 30A.

In principle, the spherical spherical powder manufacturing apparatus of the present invention can electrically connect at least one metal raw material to one of the electrodes of the arc heating unit during operation, and after the full electrode of the arc heating unit is energized, the metal raw material is matched When the arc discharge region is advanced, the electric charge connected to each electrode can enter the arc discharge region, thereby generating an arc for heating and melting the metal material.

In the embodiment shown in Figures 2 and 3, the two metal materials 10 are electrically connected to the two electrodes 31, 32 of the arc heating unit 30 respectively (i.e., the two metal materials 10 are respectively connected for use). Each of the metal materials 10 can be respectively inserted into the passage 331 of each bracket 33 of the arc heating unit 30, and the metal material 10 that is placed therethrough is guided into the arc discharge region 30A by the bracket 33, and simultaneously The charge connected thereto is directed into the arc discharge region 30A.

Therefore, when the entire electrodes 31, 32 of the arc heating unit 30 are energized, the two metal materials 10 are simultaneously pushed toward the arc discharge region 30A, so that the electric charge connected to each electrode enters the arc discharge region 30A, thereby generating simultaneous The arc of the two metal materials 10 is heated and melted.

At the same time, the gas stream generated by the first atomizing unit 40 acts on the molten metal which is melted after the metal material 10 is heated, so that the molten metal liquid is immediately subjected to the first atomization to form a plurality of fine metal droplets 11 At the same time, the plasma jet generated by the second atomizing unit 50 acts on the metal droplet 11 formed by the first atomization, so that the metal droplet 11 formed by the first atomization is atomized again (fine The formation of a plurality of fine metal particles 12 can complete the manufacture of a spherical metal powder having a plurality of fine metal particles 12.

Furthermore, the spherical metal powder manufacturing apparatus of the present invention may further comprise a feed for receiving at least one metal raw material 10 and advancing the received metal raw material 10 toward the arc discharge region 30A of the arc heating unit 30. Unit 60; In the embodiment shown in Figures 2 and 3, each of the brackets 33 of the arc heating unit 30 is provided with a passage 331 through which the metal material 10 can pass.

The feeding unit 60 is provided with at least two conveying wheels 61 for contacting the metal material 10 respectively corresponding to the respective brackets 33; wherein the metal material 10 may be a wire metal material or a rod metal material having a predetermined wire diameter. The material is advanced toward the arc discharge region 30A at a predetermined rate by the transfer wheel 61 of the feed unit 60 to continuously supply the raw materials required for the manufacture of the spherical metal powder.

Furthermore, the apparatus for manufacturing a spherical metal powder of the present invention may also be as shown in FIGS. 4 and 5, wherein the arc heating unit 30 is provided with a set of brackets 33 provided with a passage through which the metal material 10 can pass. The bracket 33 provided with the passage 331 can also be the nozzle 41 of the first atomizing unit 40 at the same time; as for the feeding unit 60, at least two metal and metal are provided corresponding to the bracket 33 provided with the passage 331 The transfer wheel 61 in contact with the raw material 10.

In the embodiment shown in FIGS. 4 and 5, a metal material 10 is electrically connected to one of the electrodes 31 of the arc heating unit 30, that is, the single metal material 10 is connected to generate a positive electric charge of the arc or The negative charge (shown as a negative charge is connected), and the metal material 10 is inserted into the channel 33 of the bracket 33 of the arc heating unit 30, and the metal material 10 that is placed by the bracket 33 and its connected The charge is directed into the arc discharge region 30A while the other set of brackets 33 are directly connected to the other electrode 32 to direct the charge connected thereto into the arc discharge region 30A.

Similarly, after the entire electrodes 31, 32 of the arc heating unit 30 are energized, the metal material 10 can be pushed toward the arc discharge region 30A by the transfer wheel 61 of the feeding unit 60, so that the electrodes can be connected. The charge enters the arc discharge region 30A, thereby generating an arc that simultaneously heats and melts the two metal materials 10.

In other words, the spherical metal powder disclosed in the present invention may be a spherical metal powder which is manufactured according to various possible methods for producing a spherical powder, and the spherical metal powder has a plurality of fine metal particles, all of which are The fine metal particles have an average particle diameter of less than 100 μm, and 92% or more of the fine metal particles have a circularity of from 1 to 1.07, and more than 92% of the fine metal particles have a ratio of the longest axis to the shortest axis of less than 1.5.

Or the spherical metal powder disclosed in the present invention is a spherical metal powder which is manufactured according to various possible spherical spherical powder manufacturing apparatuses, and the spherical metal powder has a plurality of fine metal particles, and the total number thereof The average particle diameter of the fine metal particles is less than 100 μm, and the round ratio of the fine metal particles of 92% or more is between 1 and 1.07, and the ratio of the longest axis to the shortest axis of the fine metal particles (12) of 92% or more Less than 1.5.

In a method for manufacturing a spherical powder according to a specific embodiment of the present invention, two copper wire metal materials having a diameter of 1.6 mm are respectively used as electrodes for generating an arc discharge, and the chamber is evacuated to <1×10 ^{-3 .} After Pa, a nitrogen gas of less than 0.12 to 0.15 MPa was introduced, and two copper wires of 1.6 mm in diameter were arc-discharged by a current of 120 A, and two copper wire metal materials having a diameter of 1.6 mm were heated and dissolved to produce a molten metal.

At the same time, the nitrogen gas is introduced into the arc discharge region at an inlet pressure of 0.5 MPa, and two copper metal materials having a diameter of 1.6 mm are thermally melted to be firstly atomized to form a plurality of fine copper. The metal droplets, followed by three sets of power of 25 kW each, and the plasma jet generated by the plasma torch with an inlet pressure of 0.5 MPa acts on the copper metal droplets formed by the first atomization to make it fog again. It turns into a plurality of fine copper metal particles.

The spherical metal powder produced by the specific implementation method has a plurality of fine copper metal particles, and the average particle diameter of all the fine copper metal particles is between 30 and 50 μm, and 96% or more of the fine copper metal particles are used. The round ratio is less than 1.5, and more than 95% of the fine copper metal particles have a roundness between 1 and 1.07.

In another embodiment of the method for manufacturing a spherical powder, the titanium wire metal material having a diameter of 1.6 mm is used as an electrode for generating an arc discharge, and the chamber is evacuated to <1×10 ^{− After 3} Pa, nitrogen gas of less than 0.12~0.15MPa is introduced, and two titanium wire metal materials with a diameter of 1.6mm are arc-discharged by a current of 150A, and two titanium wire metal materials with a diameter of 1.6 mm are heated and dissolved to produce a molten metal. .

At the same time, the argon gas is fed at an inlet pressure of 0.5 MPa to form a gas flow acting on the arc discharge region, and the two molten metal materials of 1.6 mm diameter of the titanium wire are subjected to the first atomization to form a plurality of fine titanium. The metal droplets, followed by three sets of power of 25 kW each, and the plasma jet generated by the plasma torch with an inlet pressure of 0.5 MPa acts on the titanium metal droplets formed by the first atomization to make it fog again. It turns into a plurality of fine titanium metal particles.

The spherical metal powder produced by the specific implementation method has a plurality of fine titanium metal particles, and the average particle diameter of all the fine titanium metal particles is between 15 and 30 μm, and more than 97% of the fine titanium metal particles are used. The round ratio is less than 1.5, and more than 94% of the fine titanium metal particles have a roundness between 1 and 1.07.

In still another embodiment of the method for manufacturing a spherical powder, two tin alloy wire metal materials having a diameter of 2.0 mm are respectively used as electrodes for generating an arc discharge, and the tin alloy wire metal material is tin-silver. - a copper alloy wire, after evacuating the chamber to <1×10 ^-3 Pa, introducing a nitrogen gas of less than 0.12 to 0.15 MPa, and causing an arc discharge of the two tin alloy wire metal materials by a current of 110 A. The two tin alloy wire metal materials are heated and dissolved to produce a molten metal.

At the same time, the nitrogen gas is introduced into the arc discharge region at an inlet pressure of 0.3 MPa, and the tin alloy metal liquid of the two tin alloy wire metal materials is subjected to the first atomization to form a plurality of fine tin alloy metals. The droplets are then sprayed by a plasma jet generated by a three-group power of 20 kW each with a gas pressure of 0.4 MPa, which acts on the tin alloy metal droplets formed by the first atomization to make it fog again. It is turned into a plurality of fine tin alloy metal particles.

The spherical metal powder produced by the specific implementation method has a plurality of fine tin alloy metal particles, and the fine tin alloy metal particles are tin-silver-copper alloy metal particles, and the average particle diameter of all the fine tin alloy metal particles is Between 25 and 45 μm, more than 95% of the fine tin alloy metal particles have a circularity of less than 1.5, and more than 92% of the fine tin alloy metal particles have a roundness of between 1 and 1.07.

Specifically, the present invention mainly applies a first atomization to form a plurality of metal droplets at a moment when the metal raw material is thermally melted into a molten metal, and then sprays the metal droplets by a plasma jet. Secondary atomization to form a plurality of fine metal particles can not only effectively reduce the thermal energy loss of the metal droplets, but also provide sufficient temperature by the plasma jet to allow the fine metal particles to converge into a spherical shape for a relatively long period of time, thereby increasing the metal powder. The purpose of the round rate; in particular, the metal liquid melted by the arc heating can effectively increase the distribution rate of the fine metal particles after the first atomization and the second atomization, in a relatively more active and reliable manner. Improve the production capacity and quality of spherical metal powder.

The embodiments described above are merely illustrative of the technical spirit and the features of the present invention, and the objects of the present invention can be understood by those skilled in the art, and the scope of the present invention cannot be limited thereto. That is, the equivalent variations or modifications made by the spirit of the present invention should still be included in the scope of the present invention.

10‧‧‧Metal materials
10A‧‧‧Spherical metal powder
11‧‧‧Metal droplets
12‧‧‧Metal particles
20‧‧‧ chamber
30‧‧‧Arc heating unit
30A‧‧‧Arc discharge area
31‧‧‧ electrodes
32‧‧‧ electrodes
33‧‧‧ bracket
331‧‧‧ channel
40‧‧‧First atomization unit
41‧‧‧Nozzles
50‧‧‧Second atomization unit
51‧‧‧Plastic Torch
60‧‧‧ Feeding unit
61‧‧‧Transport wheel

Fig. 1 is a schematic view showing the composition of the spherical metal powder of the present invention. Fig. 2 is a schematic view showing the structure of a spherical metal powder manufacturing apparatus according to a first embodiment of the present invention. Fig. 3 is an enlarged schematic view showing an arc heating unit in the apparatus for manufacturing a spherical metal powder according to the first embodiment of the present invention. Fig. 4 is a structural schematic view showing a manufacturing apparatus of a spherical metal powder according to a second embodiment of the present invention. Fig. 5 is an enlarged schematic view showing an arc heating unit in the apparatus for manufacturing a spherical metal powder according to a second embodiment of the present invention.

10‧‧‧Metal materials

11‧‧‧Metal droplets

12‧‧‧Metal particles

30‧‧‧Arc heating unit

30A‧‧‧Arc discharge area

31‧‧‧ electrodes

32‧‧‧ electrodes

33‧‧‧ bracket

331‧‧‧ channel

40‧‧‧First atomization unit

41‧‧‧Nozzles

50‧‧‧Second atomization unit

51‧‧‧Plastic Torch

60‧‧‧ Feeding unit

61‧‧‧Transport wheel

Claims (33)

A method for manufacturing a spherical powder, wherein at least one metal material (10) fed into an arc discharge region (30A) is heated and melted to form a molten metal by thermal energy of arc discharge, and a gas stream having a predetermined kinetic energy acts on the arc discharge region. (30A), the molten metal melted by the at least one metal raw material (10) is immediately subjected to a first atomization to form a plurality of fine metal droplets (11), and at the same time, at least one plasma jet is applied to the The metal droplets (11) formed by the first atomization are atomized again to form a plurality of fine metal particles (12), and the entire fine metal particles (12) are cooled and shaped to complete the manufacture of the spherical metal powder (10A). . The method for producing a spherical powder according to claim 1, wherein the method for producing the spherical powder is to perform arc discharge, first atomization, and second atomization in a closed chamber (20). The method for producing a spherical powder according to claim 1, wherein the method for producing the spherical powder is to use the at least one metal material (10) as an electrode for performing arc discharge. The method for producing a spherical powder according to claim 1, wherein the method for producing a spherical powder is to use the at least one metal material (10) as an electrode for performing arc discharge, and a closed chamber (20). The arc discharge, the first atomization, and the second atomization are performed. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the at least one metal material (10) may be titanium, tin, copper, zinc, aluminum, gold, silver, iron or nickel. One or its alloy. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the at least one metal material (10) is a wire metal material having a predetermined wire diameter. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the at least one metal material (10) is a rod metal material having a predetermined wire diameter. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the gas flow acting on the arc discharge region (30A) is air, oxygen, nitrogen, argon, helium, hydrogen and oxygen. , one of carbon monoxide, carbon dioxide, or a combination thereof. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the arc discharge region (30A) has an operating temperature of between 1000 ° C and 6000 ° C. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the at least one plasma jet has an operating temperature of between 1000 ° C and 10000 ° C. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the metal droplets (11) have an average particle diameter of between 100 and 500 μm. The method for producing a spherical powder according to any one of claims 1 to 4, wherein the fine metal particles (12) have an average particle diameter of less than 100 μm. The method for producing a spherical powder according to claim 4, wherein the method for producing the spherical powder is to use two copper wire metal materials having a diameter of 1.6 mm as electrodes for generating an arc discharge effect, in the chamber ( 20) After vacuuming to <1×10 ^-3 Pa, nitrogen gas of less than 0.12~0.15MPa is introduced, and two copper wires of 1.6mm diameter are arc-discharged by a current of 120A, and the two diameters are 1.6mm. The copper wire metal material is heated and dissolved to produce a molten metal, and at the same time, a nitrogen gas is introduced into the arc discharge region (30A) at an inlet pressure of 0.5 MPa, and two copper metal materials having a diameter of 1.6 mm are thermally melted. The first atomization is performed to form a plurality of fine copper metal droplets, and then the plasma jet generated by the plasma torch (51) having three sets of powers of 25 kW and an inlet pressure of 0.5 MPa is applied to the The copper metal droplets formed are atomized for the first time, and are again atomized into a plurality of fine copper metal particles. The method for producing a spherical powder according to claim 4, wherein the method for producing the spherical powder is to use two titanium wire metal materials having a diameter of 1.6 mm as electrodes for generating an arc discharge effect, in the chamber ( 20) After vacuuming to <1×10 ^-3 Pa, nitrogen gas of less than 0.12~0.15MPa is introduced, and the current of 150A is used to generate arc discharge of two 1.6mm diameter titanium metal materials, and the two diameters are 1.6mm. The titanium wire metal material is heated and dissolved to generate a molten metal, and at the same time, an argon gas is introduced at an inlet pressure of 0.5 MPa to form a gas flow acting on the arc discharge region (30A), and two metal materials having a diameter of 1.6 mm of the titanium wire metal material are thermally melted. The first atomization is performed to form a plurality of fine titanium metal droplets, and then the plasma jet generated by the plasma torch (51) having three sets of powers of 25 kW and an inlet pressure of 0.5 MPa is applied to the The titanium metal droplets formed are atomized for the first time, and are again atomized into a plurality of fine titanium metal particles. The method for producing a spherical powder according to claim 4, wherein the method for producing the spherical powder is to use two tin alloy wire metal materials having a diameter of 2.0 mm as an electrode for generating an arc discharge effect on the chamber. (20) After vacuuming to <1×10 ^-3 Pa, nitrogen gas of less than 0.12~0.15MPa is introduced, and the current of the two tin alloy wire metal materials is arc-discharged by the current of 110A, and the two tin alloy wire metal materials are used. The molten metal is heated and dissolved, and nitrogen gas is supplied at an inlet pressure of 0.3 MPa to form a gas flow acting on the arc discharge region (30A), and the tin alloy metal liquid in which the two tin alloy wire metal materials are thermally melted is subjected to the first atomization. A plurality of fine tin alloy metal droplets are formed, and then a plasma jet generated by a plasma torch (51) having three sets of powers of 20 kW and an inlet pressure of 0.4 MPa is applied to the first atomization chamber. The tin alloy metal droplets are formed and atomized again into a plurality of fine tin alloy metal particles. The method for producing a spherical powder according to claim 15, wherein the tin alloy wire metal material is a tin-silver-copper alloy wire. A spherical metal powder manufacturing apparatus is provided in a chamber (20): an arc heating unit (30), a first atomizing unit (40), and a second atomizing unit; wherein: the arc a heating unit (30) for connecting positive and negative charges for generating an arc discharge, and for receiving at least one metal material (10) as an electrode for generating an arc discharge, the at least one metal being generated after the electrode is energized The raw material (10) is heated and dissolved into an arc of the molten metal; the first atomizing unit (40) is configured to apply a gas stream having a predetermined kinetic energy to the arc discharge region (30A) of the arc heating unit (30), At least one metal material (10) is subjected to a first atomization by a molten metal solution to form a plurality of metal droplets (11); the second atomization unit (50) is applied to the first atomization by a plasma jet The first atomization of the formed metal droplets (11) causes the metal droplets (11) formed by the first atomization to be atomized again into a plurality of fine metal particles (12). The apparatus for manufacturing a spherical metal powder according to claim 17, wherein the arc heating unit (30) is provided with two sets of electrodes (31, 32) for respectively connecting positive and negative charges, and another two groups. The charge connected to each electrode is directed into the holder (33) of the arc discharge region (30A). The apparatus for manufacturing a spherical metal powder according to claim 17, wherein the first atomizing unit (40) is provided with at least one set of nozzles for applying a gas stream having a predetermined kinetic energy to the arc discharge region (30A). ). The apparatus for manufacturing a spherical metal powder according to claim 17, wherein the second atomizing unit (50) is provided with at least one plasma torch (51) for generating a plasma jet after energization, the at least one The plasma torch (51) is set such that the plasma jet generated thereby acts on the stroke of the airflow of the first atomizing unit (40) after passing through the arc discharge region (30A). The apparatus for manufacturing a spherical metal powder according to claim 17, wherein the arc heating unit (30) is provided with two sets of electrodes (31, 32) for respectively connecting positive and negative charges, and another two groups. The electric charge connected to each electrode is guided into the bracket (33) of the arc discharge area (30A); the first atomizing unit (40) is provided with at least one set of airflows with predetermined kinetic energy acting on the arc discharge area (30A) a nozzle (41); the second atomizing unit (50) is provided with at least one plasma torch (51) for generating a plasma jet after energization, the at least one plasma torch (51) being set The plasma jet generated thereby is applied to the flow of the first atomizing unit (40) through the arc after the arc discharge region (30A). The spherical metal powder manufacturing apparatus according to any one of claims 17 to 21, wherein the spherical metal powder manufacturing apparatus further comprises a supply of at least one metal raw material (10), and the A feed unit (60) that advances the metal material (10) toward the arc discharge region (30A). The spherical metal powder manufacturing apparatus according to any one of claims 17 to 21, wherein the spherical metal powder manufacturing apparatus further comprises a supply of at least one metal raw material (10), and the a feeding unit (60) for advancing the metal material (10) toward the arc discharge region (30A); each of the brackets (33) of the arc heating unit (30) is provided with a passage through which the metal material (10) can pass (331); the feeding unit (60) is provided with at least two conveying wheels (61) for contacting the metal material (10) corresponding to the respective brackets (33). The spherical metal powder manufacturing apparatus according to any one of claims 17 to 21, wherein the spherical metal powder manufacturing apparatus further comprises a supply of at least one metal raw material (10), and the a feeding unit (60) for advancing the metal material (10) toward the arc discharge region (30A); the arc heating unit (30) is attached to a group of brackets (33) provided with a metal material (10) Channel (331); the feeding unit (60) is provided with at least two conveying wheels (61) for contacting the metal material (10) corresponding to the bracket (33) provided with the passage (331). The apparatus for manufacturing a spherical metal powder according to claim 19, wherein at least one nozzle (41) of the first atomizing unit (40) is disposed on two sets of brackets of the arc heating unit (30). )intermediate. The apparatus for manufacturing a spherical metal powder according to claim 19, wherein at least one nozzle (41) of the first atomizing unit (40) is disposed on two sets of brackets of the arc heating unit (30). )periphery. The apparatus for manufacturing a spherical metal powder according to claim 20 or 21, wherein at least one plasma torch (51) of the second atomizing unit (50) is provided in two sets of brackets of the arc heating unit (30) (33) Periphery. A spherical metal powder obtained by using the method for producing a spherical powder according to any one of claims 1 to 16, wherein the spherical metal powder has a plurality of fine metal particles (12). The average particle diameter of all the fine metal particles (12) is less than 100 μm, and 92% or more of the fine metal particles (12) have a roundness of between 1 and 1.07, and more than 92% of the fine metal particles (12) The ratio of the longest axis to the shortest axis is less than 1.5. A spherical metal powder (10A) manufactured by using the spherical powder manufacturing apparatus according to any one of claims 17 to 27, wherein the spherical metal powder (10A) has a plurality of fine particles The metal particles (12) have an average particle diameter of all the fine metal particles (12) of less than 100 μm, and more than 92% of the fine metal particles (12) have a round ratio of between 1 and 1.07, and more than 92%. The ratio of the longest axis to the shortest axis of the fine metal particles (12) is less than 1.5. A spherical metal powder (10A) produced by the method for producing a spherical powder according to claim 13, wherein the spherical metal powder (10A) has a plurality of fine copper metal particles, all of which are The average particle size of the fine copper metal particles is between 30 and 50 μm, and more than 96% of the fine copper metal particles have a circularity of less than 1.5, and more than 95% of the fine copper metal particles have a circularity of 1 to 1.07. between. A spherical metal powder (10A) produced by the method for producing a spherical powder according to claim 14, wherein the spherical metal powder (10A) has a plurality of fine titanium metal particles, all of which are The average particle diameter of the fine titanium metal particles is between 15 and 30 μm, and the roundness of the fine titanium metal particles of 97% or more is less than 1.5, and the round ratio of the fine titanium metal particles of more than 94% is between 1 and 1.07. between. A spherical metal powder (10A) obtained by using the method for producing a spherical powder according to claim 15, wherein the spherical metal powder (10A) has a plurality of fine tin alloy metal particles. The average particle size of all the fine tin alloy metal particles is between 25 and 45 μm, and the roundness of more than 95% of the fine tin alloy metal particles is less than 1.5, and more than 92% of the fine tin alloy metal particles are rounded. Between 1~1.07. The spherical metal powder according to claim 33, wherein the fine tin alloy metal particles are tin-silver-copper alloy metal particles.