WO2019157594A1 - High melting point metal or alloy powders atomization manufacturing processes - Google Patents

High melting point metal or alloy powders atomization manufacturing processes Download PDF

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Publication number
WO2019157594A1
WO2019157594A1 PCT/CA2019/050176 CA2019050176W WO2019157594A1 WO 2019157594 A1 WO2019157594 A1 WO 2019157594A1 CA 2019050176 W CA2019050176 W CA 2019050176W WO 2019157594 A1 WO2019157594 A1 WO 2019157594A1
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WIPO (PCT)
Prior art keywords
atomization
high melting
melt
melting point
powder
Prior art date
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Ceased
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PCT/CA2019/050176
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English (en)
French (fr)
Inventor
Sylvain St-Laurent
Shizhu Chen
Hui Li
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5N Plus Inc
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5N Plus Inc
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Filing date
Publication date
Application filed by 5N Plus Inc filed Critical 5N Plus Inc
Priority to US16/970,122 priority Critical patent/US11084095B2/en
Priority to EP19754782.1A priority patent/EP3752304B1/en
Priority to JP2020543221A priority patent/JP2021514028A/ja
Priority to CN201980013688.8A priority patent/CN111727095A/zh
Priority to CA3090714A priority patent/CA3090714C/en
Priority to KR1020207023478A priority patent/KR102546750B1/ko
Publication of WO2019157594A1 publication Critical patent/WO2019157594A1/en
Anticipated expiration legal-status Critical
Priority to US17/379,373 priority patent/US11607732B2/en
Priority to JP2022152063A priority patent/JP2022191273A/ja
Ceased legal-status Critical Current

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Classifications

    • 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
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/02—Spray pistols; Apparatus for discharge
    • B05B7/10—Spray pistols; Apparatus for discharge producing a swirling discharge
    • 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
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
    • B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
    • B33Y40/10—Pre-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/02—Spray pistols; Apparatus for discharge
    • B05B7/04—Spray pistols; Apparatus for discharge with arrangements for mixing liquids or other fluent materials before discharge
    • B05B7/0416—Spray pistols; Apparatus for discharge with arrangements for mixing liquids or other fluent materials before discharge with arrangements for mixing one gas and one liquid
    • B05B7/0441—Spray pistols; Apparatus for discharge with arrangements for mixing liquids or other fluent materials before discharge with arrangements for mixing one gas and one liquid with one inner conduit of liquid surrounded by an external conduit of gas upstream the mixing chamber
    • B05B7/0466—Spray pistols; Apparatus for discharge with arrangements for mixing liquids or other fluent materials before discharge with arrangements for mixing one gas and one liquid with one inner conduit of liquid surrounded by an external conduit of gas upstream the mixing chamber with means for deflecting the central liquid flow towards the peripheral gas flow
    • 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
    • B22F2009/0824—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 with a specific atomising fluid
    • 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
    • B22F2009/0824—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 with a specific atomising fluid
    • B22F2009/0828—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 with a specific atomising fluid with water
    • 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
    • B22F2009/0832—Handling of atomising fluid, e.g. heating, cooling, cleaning, recirculating
    • 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
    • B22F2009/088—Fluid nozzles, e.g. angle, distance
    • 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
    • B22F2301/00—Metallic composition of the powder or its coating
    • B22F2301/10—Copper
    • 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
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • B22F2998/10—Processes characterised by the sequence of their steps
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the field of the disclosure pertains to the production of fine metallic powders for application in the electronic industry, metal injection forming, thermal spraying, thermal spray welding, 3D printing and catalyst materials.
  • fine powders are also seen in catalytical materials where selected precious metals or metals having multiple oxidation states are also used.
  • fine metallic powders can be produced and dispersed on a media to serve together as a catalytical material. It is not uncommon to have required or requested particle size distribution mostly under 50 and even under 20 microns for such applications.
  • the present disclosure describes a new production process for metallic powders having high melting points. This process produces fine spherical powders with a small standard deviation on the particle diameter.
  • a high melting point metal or alloy powder atomization manufacturing process comprising:
  • the atomization process may be being carried out in the presence of water within an atomization chamber used for said atomization process.
  • a high melting point metal or alloy powder atomization manufacturing process comprising:
  • the melt is diverted in the diverter at a diverting angle with respect to a central axis of the feed tube.
  • a a high melting point metal or alloy powder atomization manufacturing process comprising: providing a melt of said high melting point metal or alloy through a feed tube; directing the melt to an atomization area; and providing at least one atomization gas stream having an average gas velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder with an average particle diameter under 50 microns with geometric standard deviation of lower than about 2.2.
  • a high melting point metal or alloy powder atomization manufacturing process comprising:
  • directing the optionally diverted melt to an atomization area and providing at least one atomization gas stream having a velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000- cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder particle sizes having geometric standard deviation of lower than about 2 2
  • Figure 1 is a block diagram illustrating steps involved in the atomization process, in accordance with at least one embodiment
  • Figure 2 illustrates a schematic side view of an atomization nozzle with a feed tube with a diverting channel to provide the melt in the atomization area, in accordance with at least one embodiment
  • Figure 3 illustrates a perspective view of the atomization chamber showing tangential gas entries on the gas inlet, in accordance with at least one embodiment
  • Figures 4A and 4B illustrate scanning electron microscope (SEM) pictures of the powder obtained in Example 2, wherein Figure 4A refers to a Type 5 powder (15-25 pm) and Figure 4B refers to a the proportion of the powder under 7 pm; and
  • FIGS 5A and 5B illustrate the benefit of the new atomization technology
  • high melting point metal refers to a metal having a melting point temperature of about 500° Celsius to about 1800° Celsius.
  • high melting point alloy refers to an alloy having a liquidus temperature of about 500° Celsius to about 1800° Celsius.
  • the term“comprising” and its derivatives, as used herein, are intended to be open ended terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but do not exclude the presence of other unstated features, elements, components, groups, integers and/or steps.
  • the foregoing also applies to words having similar meanings such as the terms, “including”, “having” and their derivatives.
  • the term “consisting” and its derivatives, as used herein, are intended to be closed terms that specify the presence of the stated features, elements, components, groups, integers, and/or steps, but exclude the presence of other unstated features, elements, components, groups, integers and/or steps.
  • parameters used to characterize powders may include average size distribution, standard deviation of the size distribution, proportion of coarser particles and finer particles over/under predefined sizes, sphericity of the powder, level of metallic impurities and oxygen level.
  • the diverting angle (90-Beta) may be about 30 to about 70 degrees.
  • the diverting angle may be about 10 to about 90 degrees.
  • an angle formed between the atomization gas and the melt may be about 10 to about 90 degrees.
  • an angle formed between the atomization gas and the melt may be about 40 to about 90 degrees.
  • the process may comprise providing a high melting point metal.
  • the high melting point metal may have a melting point of about 500° Celsius to about 1800° Celsius.
  • a ratio of the atomization gas to the high melting point metal in the atomization area may be about 15 000 to about 30 000 cm 3 of gas per cm 3 of metal to atomize.
  • a ratio of the atomization gas to the high melting point metal in the atomization area may be about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize.
  • the high melting point metal may be an element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au.
  • the high melting point metal may be an element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au and Sn.
  • the high melting point metal is Cu.
  • the high melting point metal is Sn.
  • the process may include providing a high melting point alloy.
  • the high melting point alloy may have a liquidus of about 500° Celsius to about 1800° Celsius.
  • the high melting point alloy may have a liquidus of about 500° Celsius to about 1500° Celsius.
  • a ratio of atomization gas to the high melting point alloy may be about 15 000 to about 30 000 cm 3 of gas per cm 3 of metal.
  • a ratio of atomization gas to the high melting point alloy may be about 5000 to about 40 000 cm 3 of gas per cm 3 of metal.
  • the high meting point alloy may include at least one element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au.
  • the high meting point alloy may include at least one element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au and Sn.
  • the high meting point alloy comprises Cu.
  • the high meting point alloy comprises Sn.
  • the high meting point alloy comprises Cu and Sn.
  • the high melting point allow consists essentially of Cu and Sn.
  • the high melting point allow consists of Cu and Sn.
  • the atomization gas stream may have a velocity of about 300 m/s to about 700 m/s.
  • the atomization gas stream may have a velocity of about 450 m/s to about 600 m/s.
  • the atomization gas stream may have a supersonic speed.
  • the atomization gas may be delivered to an atomization head through at least one gas inlet oriented in a non-perpendicular way with respect to the atomization head, the gas inlet providing a swirl movement in the atomization head prior to the gas exit.
  • At least two gas injectors may be offset versus the central axis of the feed tube, creating a dynamic rotational effect around the central axis in the atomization area.
  • the process may thereby provide a distribution of powder particle sizes with geometric standard deviation of lower than or about 2.2.
  • the process may thereby provide a distribution of powder particle sizes with geometric standard deviation of about 1.5 to about 2.0.
  • the atomization chamber may comprise about 0 to about 20% of oxygen.
  • the water may comprise at least one additive to reduce the redox potential of the water.
  • the redox potential of the water has been reduced prior to the atomization.
  • the temperature of the water used in the atomization chamber is lowered so as to reduce the powders oxidation in the atomization process
  • the process may thereby provide powder average particle size of about 10 microns to about 50 microns in diameter.
  • the melt of said high melting point metal may be diverted through at least one melt diverting channel and the diverting angle may be formed between the central axis of the feed tube and the at least one melt diverting channel.
  • the alloy melt may be diverted through at least two melt diverting channels and the diverting angle may be formed between the central axis of the feed tube and the at least two melt diverting channels.
  • At least one jet of water may be sprayed into the atomization chamber.
  • the at least one jet of water may be sprayed on at least one wall of the atomization chamber.
  • the process may thereby provide a powder having an average particle size of less than about 50 microns.
  • the process may thereby provide a powder having an average particle size of less than about 35 microns.
  • the produced powder may be vacuum dried to avoid powders oxidation.
  • the produced powder may be washed with an organic solvent to remove most of the water prior of the drying stage.
  • an atomization device for manufacturing high melting point metal or alloy powder.
  • the device may include a feed tube for providing a melt of said high melting point metal or alloy; a diverter, in fluid flow communication with said feed tube, for diverting the melt at a diverting angle with respect to a central axis of the feed tube to obtain a diverted melt, and to directing the diverted melt to an atom ization area of the atomization device; at least one atomization gas injector for providing at least one atomization gas stream to the atomization area located inside the atomization chamber; and at least one water inlet for providing water within an atomization chamber of said atomization device.
  • the diverter may comprise a melt diverting conduit, the diverting conduit being oriented at a diverting angle with respect to a central axis of the feed tube.
  • the diverter may comprise at least two melt diverting conduits, each of the at least two melt diverting conduits being oriented at a diverting angle with respect to a central axis of the feed tube.
  • the device may comprise at least one gas inlet, the at least one gas inlet being non perpendicular to the atomization head as to provide a swirl movement in the atomization head and a dynamic rotational movement in the atomization area and the atomization chamber.
  • At least one non perpendicular gas inlets may create a circular flow in the atomization head leading to a dynamic rotational movement of the gas in the atomization area and the atomization chamber.
  • At least two gas inlets may be non perpendicular to the atomization head creating a swirling effect in the atomization head and a dynamic rotational effect in the atomization area and the atomization chamber.
  • the at least one water inlet may be located inside the atomization chamber.
  • the at least one water inlet may be suitable for providing water for cooling said powder.
  • the at least one water inlet may be suitable for providing water for transporting said powder to the sieving/drying area.
  • the at least one water inlet may be suitable for providing water for facilitating sorting/sieving of said powder.
  • the described process is based on a known concept, atomization, but with several specific improvements. These improvements include changes to the atomization head operating parameters, to the atomization chamber configuration and to the means of post processing of the powder (collection, sieving and drying) prior of packing the final product.
  • the process is designed to reach advanced product quality and high process performances.
  • Figure 1 shows a block diagram 100 of apparatus and steps involved in the atomization process, in accordance with at least one embodiment.
  • Figure 1 shows a melting furnace 102, the atomization nozzle 200, the atomization chamber 108, a powder collection system 1 12 and a sieving system 1 14.
  • the atomization gas may advantageously be an inert gas.
  • the system may be generally maintained in near inert conditions with oxygen levels much under 21 % in the atomization chamber 108. In order to save operating costs, this gas may be purified/recycled in the process.
  • the atomization manufacturing process may be carried out by the atomization nozzle 200 where the atomization gas meets with a metal flow in specific conditions described herein. Shown at Figure 1 also shows a schematic side view of the atomization nozzle 200, where the molten metal may contact the atomization gas in the atomization zone.
  • some water may be added in the atomization chamber 108 through the side nozzles 120 and 122 to help collecting the powder and to bring the liquid mixture of the powder and water to the sieving area 1 14.
  • These water addition side nozzles 120 and 122 may be oriented towards the atomization chamber walls or may be located in the atomization area to help cooling of the powder and to avoid adhesion/deformation of the particles on the atomization chamber walls.
  • Water can also be added to ease powders collection and sieving. The produced powders may then be sieved and dried. After collection of the bulk of the powder, from the liquid stream, the bulk of the powder passes into filter presses 1 16 to recover all remaining powders in suspension prior to water recycling/disposal.
  • the size distribution of the powder produced during the optimization manufacturing process can be affected by the speed at which the atomization gas hits the metal. In this regards, higher velocity of the atomization gas leads to lower size distributions of the powder. If the atomization nozzle 200 is not designed properly, a smaller portion of the metal will be meeting the atomization gas in the required conditions (atomization gas velocity and volume) and larger variations in size and shape of the produced powder may be observed. The intimate contact between the high melting point metal/alloy and the atomization gas is also important.
  • Figure 2 illustrates a schematic side view of an atomization nozzle 200.
  • the atomization nozzle 200 has a feed tube 210 with a diverting channel 216 to provide the melt in the atomization area 230.
  • the atomization nozzle described herein comprises a feed tube 210 located between the melting furnace 102 and the atomization area 230 which is equipped with a diverter 216 (also called herein as a diverting channel 216).
  • the role of this diverter 216 is to provide a better contact between the metal and the gas in the atomization zone 230.
  • the metal may be diverted in the atomization area 230 with the Beta angle being about 20 to about 60 degrees.
  • the atomization gas may be provided to the atomization area 230 at an Alpha angle of about 20 to about 35 degrees.
  • the atomization may be improved, by an enhanced gas to metal contact and higher sheer energy
  • the melt diverting angle is also defined herein as 90-Beta.
  • the Alpha angle at which the atomization gas may be provided with respect to the feed tube 210, may also have other limitations. For example, if angle Alpha is more than 60 degrees, a close to direct projection of the atomization gas on the atomization chamber walls may require larger atomization chamber diameters.
  • Alpha angle may be as low as about 20 to about 45°.
  • Alpha angle may be less than about 20 to about 45°.
  • the Alpha angle may be between about 0 to about 90°; about 10 to about 50 °; about 15 to about 50 °; about 20 to about 50 °.
  • the Alpha angle may be about 20 to about 45° where 2 Alpha may be about 40° to about 90°). In at least one embodiment, the Alpha angle may be about 20 to about 40 °; about 30 to about 45 °.
  • the density of particles in the atomization gas need to be controlled in an appropriate range. For example, if one cubic centimeter (cc) of metal is atomized in 10 microns diameter spherical particles in 1 M 3 of atomization gas, the density of particles in the plume is 1 ,9 Millions/M 3 . The use of 5M 3 of gas per cubic centimeter of metal would reduce this density by a factor 5. So an optimal range of gas volume per metal volume is critical to avoid collisions and also to provide the sheer energy to pulverize the metal in small dropplets and also providing proper heat exchange mechanism to solidify the dropplets rapidly. The use of 5000 to 40000 cm 3 of atomization gas per cubic centimeter of metal/alloy was found appropriate for the production of fine powders (under 50 microns) of high melting point metals/alloys.
  • the atomization device 150 may include at least one non-perpendicular atomization gas inlet 214 with respect to the gas feed tube axis 212, leading to a rotational movement of the atomization gas stream 240 in the atomization head 222.
  • the gas inlets 214 enter in the atomization head tangentially.
  • Figure 3 illustrates a perspective view of the atomization chamber 300 showing tangential gas inlets 31 1 and 314, in accordance with at least one embodiment.
  • This design may allow for an asymmetric atomization plume in dynamic rotation around a central axis 312.
  • This configuration of the atomization gas inlets may provide an improved particle size distribution compared to an atomizer with perpendicular gas entries with respect to the feed tube central axis 312.
  • Some high melting point metals/alloys are difficult to solidify. . If some particles touch the walls of the atomization chamber 108 and are still partially molten or close to their melting points, they can be significantly deformed to reach a flake-type morphology, agglomerate and form non spherical particles or satellites (several particles connected together).
  • the described atomization technology can use water as a cooling media. The water may be injected in direction of the atomization chamber walls to provide a film of water carrying the produced powder. The film of water may ensure that metallic powders or metal droplets are cooled at a sufficient temperature to reduce or avoid the sticking particles, satellites and/or deformed particles.
  • the water in some cases, may provide a controlled level of surface oxidation, which may also contribute to have a free flowing powder with an acceptable level of oxygen in the final product.
  • adding water in the atomization chamber may also improve material classification. Due to electrostatic forces being enhanced between fine particles, it is sometimes hard to separate particles if dry sieving is used. Some high melting point alloys/metals powders tend to agglomerate together for many reasons. For example, sintering or sticking of the particles and also for electrostatic reasons as mentioned above. While the exact reason for agglomeration is not fully known for all high melting point/alloys produced, there is a benefit for a wet sieving system for several alloys.
  • Some metallic powders may need a controlled oxidation to remain free flowing in the final product.
  • oxygen peroxide or other hydrometallurgical oxidants may be addedin the water to allow a controlled level of oxidation.
  • the powder may be left in water at a controlled temperature for a given period of time (with or without steering) to allow for a controlled oxidation of the powder.
  • the redox of the incoming water may be lowered to limit oxidation. This can be done by adding additives in the water used in the atomization process (in the chamber or in the sieving system) to reduce the level of oxygen in the final product.
  • Additives can be reducing agents, like organic additives, such as ethanol, methanol, formic acid, acetic acid, methane sulfonic or inorganic reductants.
  • Redox potential in water may also be reduced by diverse other means, including but not limited to electrochemicals system to treat incoming water, reduction of temperature, filter with reactive metal powders.
  • the dissolve oxygen in the incoming water may be controlled to limit oxidation in the product.
  • the metal film on the powder may be reduced by dissolution with mild acid (HCI, organic acids, etc.). These may be added in the water to reduce the oxide film formed at the powder surface.
  • One of the final production steps of the process is to dry the powder.
  • This step can be performed atmospherically, under vacuum or in an inert gas. Vacuum allows the drying process to operate at a lower temperature, hence reducing potential oxidation with the water.
  • water can be displaced from the powder using an organic solvent in which water is soluble. For example ethanol and methanol. After the water has been removed, the powder containing some residual organic liquid can be dried to produce a final product with low level of oxygen.
  • a high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; diverting said melt at a diverting angle with respect to a central axis of the feed tube to obtain a diverted melt; directing the diverted melt to an atomization area; and providing at least one atomization gas stream to the atomization area. Said atomization process being carried out in the presence of water within an atomization chamber used for said atomization process.
  • the high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; delivering said melt through a diverter to an atomization area; providing at least one atomization gas stream to the atomization area; delivering water to an atomization chamber used for said atomization process, wherein, prior to being delivered to the atomization area, the melt is diverted in the diverter at a diverting angle with respect to a central axis of the feed tube.
  • the high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; directing the melt to an atomization area; and providing at least one atomization gas stream having an average gas velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder with an average particle diameter under 50 microns with geometric standard deviation of lower than about 2.0.
  • the high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; directing the melt to an atomization area; and providing at least one atomization gas stream having an average gas velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder with an average particle diameter under 435 microns with geometric standard deviation of lower than about 2.2.
  • the high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; directing the melt to an atomization area; and providing at least one atomization gas stream having an average gas velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder with an average particle diameter under 350 microns with geometric standard deviation of lower than about 2.0.
  • the high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; directing the melt to an atomization area; and providing at least one atomization gas stream having an average gas velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder with an average particle diameter under 50 microns with geometric standard deviation of lower than about 2.2.
  • a high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; optionally diverting said melt at a diverting angle with respect to a central axis of the feed tube to obtain an optionally diverted melt; directing the optionally diverted melt to an atomization area; and providing at least one atomization gas stream having a velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000- cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder particle sizes having geometric standard deviation of lower than about 2.0.
  • a high melting point metal or alloy powder atomization manufacturing process may include providing a melt of said high melting point metal or alloy through a feed tube; optionally diverting said melt at a diverting angle with respect to a central axis of the feed tube to obtain an optionally diverted melt; directing the optionally diverted melt to an atomization area; and providing at least one atomization gas stream having a velocity of at least 300 m/s, to the atomization area, wherein a ratio of the atomization gas to the high melting point metal in the atomization area is about 5 000 to about 40 000- cm 3 of gas per cm 3 of metal to atomize, thereby providing a distribution of powder particle sizes having geometric standard deviation of lower than about 2.2.
  • the diverting angle (90-Beta) may be about 30 to about 70 degrees.
  • the diverting angle may be about 10 to about 90 degrees.
  • an angle formed between the atomization gas and the melt may be about 10 to about 90 degrees.
  • an angle formed between the atomization gas and the melt may be about 40 to about 90 degrees.
  • the process may also include providing a high melting point metal.
  • the high melting point metal may have a melting point of about 500° Celsius to about 1800° Celsius.
  • a ratio of the atomization gas to the high melting point metal in the atomization area may be about 15 000 to about 30 000 cm 3 of gas per cm 3 of metal to atomize. In at least one embodiment, the ratio of the atomization gas to the high melting point metal in the atomization area may be about 5 000 to about 40 000 cm 3 of gas per cm 3 of metal to atomize.
  • the high melting point metal may be an element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au. .
  • the high melting point metal may be an element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au and Sn.
  • the high melting point metal is Cu.
  • the high melting point metal is Sn.
  • the process may comprise providing a high melting point alloy.
  • the high melting point alloy may have a liquidus between about 500° Celsius to about 1800° Celsius.
  • the high melting point alloy may have a liquidus of about 500° Celsius to about 150000° Celsius.
  • a ratio of atomization gas to the high melting point alloy may be about 15 000 to about 30 000 cm 3 of gas per cm 3 of metal.
  • a ratio of atomization gas to the high melting point alloy may be about 5000 to about 40 000 cm 3 of gas per cm 3 of metal.
  • the high meting alloy may comprise at least one element chosen from Al, Fe, Ni, Co, Cr, Mn, Si, Ti, Ag, Cu, Mo, Pt, Pd, Au and Sn.
  • the high meting point alloy comprises Cu and Sn.
  • the high meting point alloy comprises Cu.
  • the high meting point alloy comprises Sn.
  • the high melting point allow consists essentially of Cu and Sn.
  • the high melting point allow consists of Cu and Sn.
  • the atomization gas stream may have a velocity of about 300 m/s to about 700 m/s. In at least one embodiment, the atomization gas stream may have a velocity of about 450 m/s to about 600 m/s. In at least one embodiment, the atomization gas stream may have a supersonic speed.
  • the atomization gas may be delivered to an atomization head through at least one gas inlet 314, 31 1 oriented in a non-perpendicular way with respect to the metal feed tube axis 312, providing a swirl movement of the atomization gas stream 240 in the atomization head 222 prior to the gas exit.
  • At least two gas inlets 31 1 , 314 may be tangential versus the central axis 312 of the feed tube 310. This configuration may create a dynamic rotational effect around the central axis 312 of the atomization plume in the atomization chamber 108.
  • a distribution of powder particle sizes with geometric standard deviation may be lower than or about 2.2. In at least one embodiment, a distribution of powder particle sizes with geometric standard deviation may be of about 1 .5 to about 2.2.
  • a distribution of powder particle sizes with geometric standard deviation may be lower than or about 1 .8. In at least one embodiment, a distribution of powder particle sizes with geometric standard deviation may be of about 1 .5 to about 2.0.
  • the atomization chamber 108 may comprise about 0 to about 20% of oxygen.
  • the water may comprise at least one additive to control the redox potential of the water.
  • additives comprise but are not limited to ethanol, methanol, acetic acid, HCI, H2O2.
  • powder average particle size may be of about 10 microns to about 50 microns in diameter.
  • the melt of the high melting point metal may be diverted through at least one melt diverting channel and the diverting angle is formed between the central axis of the feed tube and the at least one melt diverting channel.
  • the alloy melt may be diverted through at least two melt diverting channels (diverters) 216 and the diverting angle (90°-Beta) may be formed between the central axis 212 of the feed tube 210 and the at least two melt diverting channels 216.
  • at least one jet of water is sprayed into the atomization chamber 108.
  • the at least one jet of water is sprayed on at least one wall of the atomization chamber 108.
  • a powder may have an average particle size of less than about 50 microns. In at least one embodiment, a powder may have an average particle size of less than about 350 microns.
  • the produced powder may be dried in vacuum to avoid powders oxidation.
  • the produced powder may be washed with an organic solvent to remove most of the water prior of the drying stage.
  • the organic solvent may be ethanol or methanol.
  • the atomization device 150 for manufacturing high melting point metal or alloy powder includes a feed tube 210 for providing a melt of said high melting point metal or alloy; a diverter 216, in fluid flow communication with said feed tube 210, for diverting the melt at a diverting angle with respect to a central axis of the feed tube 210 to obtain a diverted melt, and to directing the diverted melt to an atomization area 230 of the atomization device 150; at least one atomization gas injector 214 for providing at least one atomization gas stream 240 to the atomization area located inside the atomization chamber 108; and at least one water inlet 122 for providing water within an atomization chamber 108 of said atomization device 150.
  • the diverter 216 may have a melt diverting conduit 218, the diverting conduit 218 being oriented at a diverting angle with respect to a central axis 212 of the feed tube 210.
  • the diverter 216 may have at least two melt diverting conduits 218, each of the at least two melt diverting conduits 218 being oriented at a diverting angle with respect to a central axis 212 of the feed tube 210.
  • the atomization device 150 may have at least one gas inlet 214 (or 31 1 , 314).
  • the at least one gas inlet 31 1 , 314 of an exemplary embodiment of the atomization device 300 may be tangential or at least non perpendicular to the atomization head 310 to provide a swirl movement of the atomization gas stream 240, in the atomization head 222 and a dynamic rotational movement of the atomization plume in the atomization chamber 108.
  • At least one non perpendicular gas inlets (e.g. 31 1 , 314) with respect to the atomization manifold 310 may create a swirl movement of the atomization gas stream 240 in the atomization head 222 leading to a dynamic rotational movement of the atomization plume in the atomization chamber 108.
  • At least two gas inlets 214 may be non perpendicular to the atomization head 222 creating a swirling effect in the atomization head 222 and a dynamic rotational effect in the atomization area 230 and the atomization chamber 108.
  • the at least one water inlet (e.g. 122 or 120 on Fig. 1 ) may be located inside the atomization chamber 108.
  • the at least one water inlet (e.g. 122 or 120 on Fig. 1 ) may be suitable for providing water for cooling said powder.
  • the at least one water inlet (e.g. 122 or 120 on Fig. 1 ) may be suitable for providing water for transporting said powder to the sieving/drying area.
  • the at least one water inlet can be suitable for providing water for facilitating sorting/sieving of the powder.
  • Table 2A shows the atomization conditions of the test of Example 1 .
  • Figures 4A and 4B show SEM pictures of the powder obtained in the Example 2
  • Morphology as determined with a Malvern Morphology equipment was measured.
  • the circularity of the powder particles was about 0.992 in the 15-25 microns size fraction and 0.972 in particles size over 25 microns (the circularity is 1 for perfect spheres).
  • Figures 5A and 5B illustrate the benefit of the new atomization technology (new-C) compared to a reference conventional “Convergent-Divergent (conv-CD)” atomizer, wherein Figure 5A indicates a lower standard deviation in size distribution for the new technology and Figure 5B indicates a higher yield inside a prescribed particle size range for the new technology.
  • EXAMPLE 4 Copper-Tin alloys

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JP2020543221A JP2021514028A (ja) 2018-02-15 2019-02-12 高融点金属または合金粉末アトマイズ製造プロセス
CN201980013688.8A CN111727095A (zh) 2018-02-15 2019-02-12 高熔点金属或合金粉末雾化制造方法
CA3090714A CA3090714C (en) 2018-02-15 2019-02-12 High melting point metal or alloy powders atomization manufacturing processes
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US17/379,373 US11607732B2 (en) 2018-02-15 2021-07-19 High melting point metal or alloy powders atomization manufacturing processes
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