US20080093045A1 - Method for Producing Metal Products - Google Patents

Method for Producing Metal Products Download PDF

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Publication number
US20080093045A1
US20080093045A1 US11/629,658 US62965805A US2008093045A1 US 20080093045 A1 US20080093045 A1 US 20080093045A1 US 62965805 A US62965805 A US 62965805A US 2008093045 A1 US2008093045 A1 US 2008093045A1
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United States
Prior art keywords
metal
atomized
gas
melted
semifinished product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/629,658
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English (en)
Inventor
Karl Rimmer
Gunther Schulz
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Individual
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Individual
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Filing date
Publication date
Priority claimed from AT0102804A external-priority patent/AT413702B/de
Application filed by Individual filed Critical Individual
Publication of US20080093045A1 publication Critical patent/US20080093045A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B22D23/003—Moulding by spraying metal on a surface
    • 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
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/115—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces by spraying molten metal, i.e. spray sintering, spray casting
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123—Spraying molten metal

Definitions

  • the invention relates to a process for producing products from metal, especially powders, foils, coatings and molded parts, such as pins, pipes or sheets, from metals, which are used in the form of a semifinished product.
  • reactive metals such as titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, rhenium and their alloys and of superalloys (alloys based on nickel or cobalt) are largely determined by their purity, especially by the absence of oxides and ceramic impurities. Due to the high melting points of these metals and alloys and their mechanical properties, forming processes and metal cutting shaping processes are very complex.
  • U.S. Pat. No. 6,043,451 A discloses a process for plasma coating of components and for spray compacting of nickel-titanium alloy foils.
  • the metal is supplied to a plasma torch as a powder or wire in the process known from U.S. Pat. No. 6,043,451 A.
  • the production of powder and wire is very complex and expensive and requires at least one production stage proceeding from a (large-format) semifinished product. For powdered metal there is moreover the increased danger of absorption of oxygen due to the large surface.
  • Atomization of liquids by gas atomization is known.
  • DE 197 58 111 A discloses a process for producing metal powders.
  • the metal melt emerges in the form of a film from a nozzle with a slotted exit opening.
  • the film is stabilized by a laminar gas flow in a Laval gas nozzle and is then finely atomized.
  • the productivity of the nozzle system can be changed at will by lengthening the nozzle slot without adverse effects on the powder quality.
  • DE 41 02 101 A discloses a process in which metals in the form of a vertically arranged bar with radial-symmetrical cross section are melted off under an inert atmosphere by induction on the bottom end. The melt drips under the influence of gravity and electromagnetic pressure (resulting from the induction coil). The drops are then atomized by a gas flow emerging from an annular gap nozzle into a relatively coarse powder with an average grain size of roughly 50 microns with a wide grain size distribution. The metal bar is turned around its longitudinal axis during melting-off and guided into the induction coil according to consumption. For this purpose a complex drive is necessary. Gas consumption per kilogram of metal powder is high. Fine powders with a grain size less than 30 microns can only be produced with low yield. The total productivity of the process known from DE 41 02 101 A is low at roughly 20 kg/hour and cannot be increased without adverse effects on powder quality.
  • the object of this invention is to make available a process of the initially mentioned type with which direct conversion of metal which is present for example as a commercially available semifinished product into powders, metal foils, surface coatings or products of another format (semifinished products) is possible with high productivity, good economy and without the danger of introducing impurities.
  • metal in the form of a commercially available semifinished product which has for example the shape of a cuboid is melted without contact and atomized into a linear, especially wedge-shaped spray jet.
  • This spray jet is used to produce the desired metal product.
  • various products can be produced from metal.
  • metal powders can be produced, its being especially advantageous in embodiments that producing metal powders from reactive metals is possible by the process as claimed in the invention.
  • metal impurities are precluded or are for the most part prevented.
  • other metal products can be produced by for example surfaces being coated or semifinished products such as foils, sheets or pins being produced.
  • the metal of the semifinished product can be melted, atomized, sprayed onto a carrier and hardened on the carrier.
  • the process as claimed in the invention can also be used for example for coating of workpieces.
  • a semifinished product for example a pin, of metal which has an essentially rectangular cross sectional shape can be inductively melted on the surface of the two lengthwise sides of its front.
  • the front side which is melting off is located within a laminar gas flow of a linear nozzle.
  • the two halves of the linear Venturi nozzle consist preferably of a material which does not couple to the magnetic field of the induction heating.
  • tubes of metal are embedded in the Venturi half nozzle and are used as conductors for the inductive exciter current with simultaneous cooling by a cooling fluid, for example, water.
  • the tubes are for example each connected to one another via other tubes on the ends of the Venturi half nozzle.
  • the gas flows extend over the melting surface of the semifinished product which is supplied in the form of a pin and convey the melt in the form of two very thin films to the tip of the pin.
  • the two films combine here and the resulting melt film is further stabilized by the laminar gas flow, accelerated and finally atomized into fine droplets.
  • liquid (melt) film need not emerge from the nozzle with motion directed down.
  • the process as claimed in the invention works independently of the location, therefore not only vertically up, but also horizontally or vertically down, and in any other alignment.
  • the guidance of the liquid film, especially of the film of metal melt, by the gas flow is stronger than the force of gravity acting on the melt.
  • the independence of the location of the atomizing nozzle gives to the designer of nozzle systems as claimed in the invention creative degrees of freedom which can be used in a reduction of the overall height of the system.
  • the process as claimed in the invention is carried out in a tank, in the embodiment essentially continuous production of metal products being possible by a new semifinished product being connected to the semifinished product which has almost been consumed by melting off, for example connected by a weld.
  • a new semifinished product being connected to the semifinished product which has almost been consumed by melting off, for example connected by a weld.
  • FIG. 1 schematically shows one arrangement for executing the process as claimed in the invention
  • FIG. 2 shows another arrangement for executing the process as claimed in the invention
  • FIG. 3 a shows a coating as is available in the prior art (U.S. Pat. No. 6,043,451 A) and
  • FIG. 3 b shows a coating as can be produced in an application of the process as claimed in the invention.
  • FIG. 1 is a sample application of the process as claimed in the invention for producing a foil from metal.
  • This arrangement consists of a longish (linear) gas nozzle 1 in which there are water-cooled copper tubes 2 .
  • the copper tubes 2 are used to produce an inductive magnetic field.
  • the semifinished product 3 of metal to be processed with an essentially rectangular cross section is inserted into the elongated input opening of the gas nozzle 1 and is melted under the action of the inductive magnetic field without contact on its lengthwise sides.
  • a gas flow 4 which is directed by a means which is not detailed at the elongated mouth of the gas nozzle 1 and which is preferably symmetrical, therefore pointed from the two sides of the semifinished product 3 into the gas nozzle 1 , entrains the molten metal and conveys it with formation of a thin film 5 through the mouth the gas nozzle 1 .
  • the gas nozzle 1 used in the invention can be made as a Laval nozzle or as a Venturi nozzle. After passage through the narrowest point of the gas nozzle 1 (its elongated mouth) the film 5 of metal melt is atomized into a linear, wedge-shaped, especially tent-shaped spray jet 6 .
  • the spray jet 6 in this embodiment is pointed at a continuous and cooled metal belt 7 as the carrier.
  • the droplets of molten metal are liquid or still at least partially liquid at the time of impact on the metal belt 7 and solidify into a metal foil 8 with a homogenous surface (except for the two edges).
  • the metal foil 8 can be wound into a roll 9 of foil after its complete solidification which can be supported by forced cooling, and detachment from the metal belt 7 .
  • FIG. 3 a shows the spray result with a conventional round nozzle (compare U.S. Pat. No. 6,043,451 A) in which several metal beads 1 to 4 are sprayed next to one another.
  • FIG. 3 b shows a metal foil 8 which has been produced with the process as claimed in the invention, in which in a single spraying process a uniformly thicker metal layer (foil 8 ) is formed.
  • the productivity of the process of the invention can be optionally set via the length of the spray jet and via the melting heat output of the induction heating.
  • the metal added as raw material preferably in the form of a semifinished product is converted into the desired end product in one working cycle, therefore comes into contact only with the atomization gas and when the purity of the gas atmosphere is high enough, can be converted into the metal product without an increase of impurities.
  • reactive metal or alloy is thermally compacted by spray compacting, the parent material in the form of the semifinished product being melted without contact, especially inductively, and atomized into a linear, wedge-shaped spray jet.
  • the particles of the spray jet are allowed to solidify for example into a metal powder, are spray compacted on a substrate for a product, or are applied as a surface coating to a component.
  • any metals especially reactive metals such as titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, rhenium or an alloy based on these metals can be processed.
  • the process as claimed in the invention is suited for processing of a nickel-titanium alloy or a superalloy based on nickel or cobalt.
  • the semifinished product to be processed is a composite material of high-melting phases and a low-melting binder matrix.
  • the high-melting phase can be a carbide.
  • One advantage of the process as claimed in the invention is that the purity of the product differs only slightly from the purity of the parent material (semifinished product).
  • dispersoids are added specifically via another nozzle.
  • These dispersoids can be the following for example: silicon carbide, tungsten carbide, corundum (Al 2 O 3 ) or zirconium oxide.
  • the purpose of adding these dispersoids and other additives which can also be volatile is to influence the properties of the process product in the desired direction.
  • a separating agent can be applied to the substrate before spray compacting.
  • the process as claimed in the invention can be carried out especially as described below on one example in the production of a metal powder.
  • a titanium bar with a rectangular cross section (initial dimensions: width 50 mm, thickness 40 mm, length 3000 mm) is floating zone-melted with an induction frequency of 350 kHz and atomized at 5 kg/min.
  • a new bar after it has passed the preliminary lock chamber with being rendered inert and pressure equalization is brought to the end of the first bar facing away from the atomization, and the two bars are welded to one another linearly by means of a laser jet without filler on their two sides facing away from the melting assembly.
  • the weld keeps the two bars together until it finally reaches the melting zone itself and is melted at the same time.
  • the actual atomization process can be carried out continuously and economically.
  • a gas pressure of 30 bar in the pipeline in front of the linear gas nozzle a powder with an average grain size of 9.0 microns is obtained.
  • FIG. 2 A device which is suitable for this purpose for example is shown in FIG. 2 .
  • This device has a linear gas nozzle 10 with internal supply of the primary atomization gas 13 .
  • An induction coil 12 is integrated into the linear gas nozzle 10 .
  • primary atomization gas 13 emerges from the linear gas nozzle 10 , symmetrically in the illustrated embodiment, so that there are two streams of primary atomization gas 13 .
  • the linear gas nozzle 10 there is a secondary gas flow 14 which forms a melt film 21 on the metal which melts off the metal bar 15 with a rectangular cross section.
  • the melting metal bar 15 is advanced by rotationally driven guide rolls 18 toward the gas nozzle 10 .
  • the primary gas flows 13 are produced by the atomization gas which is supplied primarily within the gas nozzle 10 .
  • the primary gas flows 13 produce a local underpressure by which gas is intaken which forms the secondary gas flows 14 which are used as the support gas.
  • the entire arrangement is accommodated in a housing 19 which is filled with an inert gas, especially argon, the gas in the housing 19 being at the same pressure as the tank vicinity.
  • an inert gas especially argon
  • the metal bar 15 can be for example a titanium bar. Under the action of the primary atomization gas flows 13 a spray jet of metal droplets 22 is formed from the melt film 21 . These droplets of molten metal 22 can solidify into a powder, or, as is described by FIGS. 1 and 2 b , can be spray-compacted.
  • another metal bar with a rectangular cross section can be added onto the melting metal bar 15 by the former bar being connected to the metal bar 15 by two welds 17 which are aligned especially parallel to the plane of the drawing in FIG. 2 .
  • the following metal bar 16 is likewise guided by rotationally driven guide rolls 18 .
  • the metal of the semifinished product 15 is melted by an inductive magnetic field 12 , atomized and allowed to solidify in a chamber 25 into a powder or is sprayed onto a carrier and hardened on the carrier.
  • the molten metal is supplied in a gas nozzle 10 which is made either as a Laval nozzle or as a Venturi nozzle, as a film 21 which is stabilized by gas flows 14 , and is then atomized by other gas flows 13 .
US11/629,658 2004-06-17 2005-06-16 Method for Producing Metal Products Abandoned US20080093045A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
AUA-1028/2004 2004-06-17
AT0102804A AT413702B (de) 2004-06-17 2004-06-17 Verfahren zum herstellen von erzeugnissen aus metall
AT13222004 2004-08-02
AUA-1322/2004 2004-08-02
PCT/AT2005/000214 WO2005123305A2 (de) 2004-06-17 2005-06-16 Verfahren zum herstellen von erzeugnissen aus metall

Publications (1)

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US20080093045A1 true US20080093045A1 (en) 2008-04-24

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US11/629,658 Abandoned US20080093045A1 (en) 2004-06-17 2005-06-16 Method for Producing Metal Products

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US (1) US20080093045A1 (de)
EP (1) EP1765536B1 (de)
AT (1) ATE425832T1 (de)
CA (1) CA2570924A1 (de)
DE (1) DE502005006882D1 (de)
WO (1) WO2005123305A2 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105899312A (zh) * 2013-12-20 2016-08-24 那诺沃有限两合公司 用于无坩埚熔化材料，雾化熔化的材料及制造粉末的方法和装置
FR3054462A1 (fr) * 2016-07-29 2018-02-02 Safran Aircraft Engines Procede d'atomisation de gouttes metalliques en vue de l'obtention d'une poudre metallique
US10422018B2 (en) 2013-05-17 2019-09-24 G. Rau Gmbh & Co. Kg Method and device for remelting and/or remelt-alloying metallic materials, in particular Nitinol
CN114245762A (zh) * 2019-08-15 2022-03-25 Ald真空技术有限公司 分离导电液体的方法以及装置

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102006051936B4 (de) * 2006-11-01 2014-03-20 Zollern Bhw Gleitlager Gmbh & Co. Kg Verfahren zur Herstellung zweier miteinander verbundener Schichten und nach dem Verfahren herstellbares Funktionsbauteil
CN108247075A (zh) * 2018-04-23 2018-07-06 安徽哈特三维科技有限公司 一种用于气雾化法制备超高温金属球形粉体的雾化器装置

Citations (9)

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Publication number Priority date Publication date Assignee Title
US2864137A (en) * 1952-10-25 1958-12-16 Helen E Brennan Apparatus and method for producing metal strip
US3775156A (en) * 1970-06-20 1973-11-27 Vandervell Products Ltd Method of forming composite metal strip
US4822267A (en) * 1985-09-24 1989-04-18 Alfred Walz Apparatus for producing superfine powder in spherical form
US4830084A (en) * 1974-06-28 1989-05-16 Singer Alfred R E Spray casting of articles
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
US5284329A (en) * 1991-01-25 1994-02-08 Leybold Alktiengesellschaft System for the production of powders from metals
US5609922A (en) * 1994-12-05 1997-03-11 Mcdonald; Robert R. Method of manufacturing molds, dies or forming tools having a cavity formed by thermal spraying
US6254661B1 (en) * 1997-08-29 2001-07-03 Pacific Metals Co., Ltd. Method and apparatus for production of metal powder by atomizing
US6652804B1 (en) * 1998-04-17 2003-11-25 Gkn Sinter Metals Gmbh Method for producing an openly porous sintered metal film

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JPS6217103A (ja) * 1985-07-16 1987-01-26 Tanaka Kikinzoku Kogyo Kk 金属粉末の製造方法

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2864137A (en) * 1952-10-25 1958-12-16 Helen E Brennan Apparatus and method for producing metal strip
US3775156A (en) * 1970-06-20 1973-11-27 Vandervell Products Ltd Method of forming composite metal strip
US4830084A (en) * 1974-06-28 1989-05-16 Singer Alfred R E Spray casting of articles
US4822267A (en) * 1985-09-24 1989-04-18 Alfred Walz Apparatus for producing superfine powder in spherical form
US5022455A (en) * 1989-07-31 1991-06-11 Sumitomo Electric Industries, Ltd. Method of producing aluminum base alloy containing silicon
US5284329A (en) * 1991-01-25 1994-02-08 Leybold Alktiengesellschaft System for the production of powders from metals
US5609922A (en) * 1994-12-05 1997-03-11 Mcdonald; Robert R. Method of manufacturing molds, dies or forming tools having a cavity formed by thermal spraying
US6254661B1 (en) * 1997-08-29 2001-07-03 Pacific Metals Co., Ltd. Method and apparatus for production of metal powder by atomizing
US6652804B1 (en) * 1998-04-17 2003-11-25 Gkn Sinter Metals Gmbh Method for producing an openly porous sintered metal film

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10422018B2 (en) 2013-05-17 2019-09-24 G. Rau Gmbh & Co. Kg Method and device for remelting and/or remelt-alloying metallic materials, in particular Nitinol
CN105899312A (zh) * 2013-12-20 2016-08-24 那诺沃有限两合公司 用于无坩埚熔化材料，雾化熔化的材料及制造粉末的方法和装置
KR20160101004A (ko) * 2013-12-20 2016-08-24 나노발 게엠베하 운트 코. 카게 분말 제조를 위해 도가니 없이 재료를 용융하고 용융된 재료를 무화하기 위한 장치 및 방법
US20160318105A1 (en) * 2013-12-20 2016-11-03 Nanoval Gmbh & Co. Kg Device and method for melting a material without a crucible and for atomizing the melted material in order to produce powder
US10946449B2 (en) * 2013-12-20 2021-03-16 Nanoval Gmbh & Co. Kg Device and method for melting a material without a crucible and for atomizing the melted material in order to produce powder
KR102304964B1 (ko) * 2013-12-20 2021-09-27 나노발 게엠베하 운트 코. 카게 분말 제조를 위해 도가니 없이 재료를 용융하고 용융된 재료를 무화하기 위한 장치 및 방법
FR3054462A1 (fr) * 2016-07-29 2018-02-02 Safran Aircraft Engines Procede d'atomisation de gouttes metalliques en vue de l'obtention d'une poudre metallique
CN114245762A (zh) * 2019-08-15 2022-03-25 Ald真空技术有限公司 分离导电液体的方法以及装置
US11919089B2 (en) 2019-08-15 2024-03-05 Ald Vacuum Technologies Gmbh Method and device for breaking up an electrically conductive liquid

Also Published As

Publication number Publication date
CA2570924A1 (en) 2005-12-29
WO2005123305A2 (de) 2005-12-29
EP1765536A2 (de) 2007-03-28
DE502005006882D1 (de) 2009-04-30
ATE425832T1 (de) 2009-04-15
EP1765536B1 (de) 2009-03-18
WO2005123305A3 (de) 2006-06-01

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