| Customization: | Available |
|---|---|
| After-sales Service: | One Site Training and Installation |
| Warranty: | One Year |
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1. Introduction
RF plasma has the good features of high energy density, high heating intensity, plasma arc of large volume, simple process, etc. Also because it is electrodeless there is no pollution on product caused by electrode evaporation.
Principle: inert gas (argon) is ionized to be stable plasma torch of high temperature argon under the effect of high frequency power supply; raw materials of powder are introduced into plasma torch by carrier gas (nitrogen) through powder feeder, powder particles absorb much heat when in plasma torch of high temperature and their surfaces melt rapidly; powders are introduced into reactor at a tremendous rate and then they are cooled fastly under inert gas and solidified into spherical powder under the effect of surface tension; and powders are collected in the collector.
2. Features
1. High heating temperature, fast cooling speed, and no electrode pollution;
2. Reacting materials being distributed dynamically in plasma, avoiding agglomeration and growth of powder, suitable for melting and spheroidizing;
3. Manufacturing powder of high melting metal and oxide, such as Mo, Ti, W, WC, aluminium oxide, silicon oxide, zirconium oxide, etc;
4. Regular powder shape with spheroidization rate of over 90%; smooth and bright surface; good flowability; and increasing powder compactness and bulk density.
3. Technical Parameters
1. Total power: 100kW;
2. RF torch: 100kW, 3MHz;
3. Capacity: 3-4kg/h;
4. Ultimate vacuum degree: 8*10-2Pa;
5. Total power of the whole equipment: 150kW.
4. Equipment Structures
RF plasma spheroidization powder manufacturing equipment is mainly consisted of the following parts:
1. RF plasma torch;
2. RF plasma power supply;
3. Gas and powder feeding system;
4. Reactor-collector and holder;
5. Vacuum pumping system;
6. Electrical controlling and measuring system;
7. Water chiller unit;
Skyline's Plasma Spheroidization Equipment for Improved Metal Powder Flow and Packing Properties
To achieve optimum flow characteristics and high packing density, an ideal Additive Manufacturing (AM) metal powder should be highly spherical in shape with no satellites. Asspherical particles have minimum surface area to volume ratio this brings an added advantage in principle, of reduced surface contamination e.g. oxygen pick up. Increased particle sphericity can improve powder feeding, resulting in smoother layers, improved packing density, increased heat conduction in the powder bed and an enhanced melting profile. Generating a component by AM, also known as metal 3D Printing, relies on building the final design through a series of many thousands of layers. Whilst different metal powders can be selected according to the required performance of the final part, reproducible behavior of the powder throughout the process is key to a successful build.
Plasma Spheroidization
In principle, any metallic powder can be plasma treated to improve the flow and packing properties of low sphericity, irregular, sponge-like, agglomerated and angular metallic powders produced by other methods e.g. water atomization, chemical and mechanical processes, and standard gas-atomization. This case study presents the results of Skyline's plasma spheroidization process on morphology, flow, and packing properties of three different metallic powders - pure Tungsten (W), Ti6Al4V, and pure Tantalum (Ta).
Results
Several trials have been performed for each powder feedstock to determine the optimum processing parameters. The powder samples were fully characterized after each plasma treatment trial and compared with those of the starting feedstock.
The results demonstrate that when spheroidization parameters are optimized for the particular feedstock, particle morphology, powder flow and packing properties are significantly improved.
Plasma Spheroidisation Conclusion Morphology and packing density have a significant effect on the quality of the powder layer and melting behavior, depending on deposition system. Plasma Spheroidization at Skyline has been shown to be an effective method of controlling the shape, flow and packing characteristics to defined specifications across a range of metallic powders to deliver reliable, reproducible performance. At Skyline, we have a wealth of expertise in metal AM, and extensive experience of working with leading companies within the aerospace, biomedical, and automotive industries. We utilize this knowledge and the capabilities of plasma technology to provide solutions across a wide range of industries and AM platforms.
Advantages of Plasma Spheroidization
One of the things that makes additive manufacturing different from subtractive manufacturing is that the properties of the material are created along with the part. This is something that AM users must consider in designing the part and setting the parameters for the additive build; however, the extent to which a build can truly be controlled depends on the metal powder itself. Better powder-denser, cleaner and more spherical-behaves more predictably and thus results in better parts.
The spheroidization process works by passing raw material-angular particles of metal or previously used powders-through high-energy plasma gas. The material melts and is reformed into spherical particles with few satellites (smaller particles that stick to larger ones); this results in a batch of powder that is more suitable for AM.
The plasma spheroidization process can be highly controlled, down to the size of the particles. This is in contrast to gas atomization, which passes materials through argon or nitrogen gas and is how the majority of metal powders for additive manufacturing are made. Gas atomized materials are mostly spherical, but tend to have some asymmetric particles and satellites. Compared to gas atomization, plasma spheroidization can provide more consistent results in manufacturing or recycling powders.
For the end user, the process offers both physical and chemical advantages. The more spherical powder has better flowabilty inside an AM machine, meaning less downtime and faster production. Additionally, the plasma spheroidization process removes contamination and reduces oxygen that can accumulate when powder is re-used. Removing excess oxygen from the material helps improve mechanical properties in the final part.
So far Skyline's(skylinesmart.en.made-in-china.com) end users has used plasma spheroidization to produce powders from tantalum, tungsten and titanium alloys. Other refractory metals are in the works, such as molybdenum and niobium, as well as nickel-based super alloys. The process is not suitable for all materials, as the heat of the plasma can cause metals with lower melting points to vaporize.
Perhaps more significantly, the technology also has value for recycling used materials. Using the plasma spheroidization equipment to process old powders, Skyline's testing lab(skylinesmart.en.made-in-china.com) has the capability to blend batches of materials and resize the particles. Testing in the company's lab is performed before and after processing to verify the properties of
the powder and ensure it is comparable to virgin material. Recycling metals via plasma spheroidization reduces material costs for the user, but also help to ensure the quality of the recycled powder.
We can provide high pressure water atomization equipment, gas atomization equipment, vacuum gas atomization equipment, plasma atomization and centrifugal atomization of each batch of 3~1000KG Class. They can be used to produce iron-based powder, nickel-based powder, copper-based powder, silver-based powder, Ti, Mg, Al, Mo, W, SS and many other particle sized alloy powders. We can also customize equipment according to client's special requirements.
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