Powder production for powder metallurgy

Abstract

The present disclosure relates to a spray forming method for producing metal ingots and metal powder from a metal source of a metal or a metal alloy, comprising the steps of forming one or more streams of a metal or a metal alloy from the metal source, gas atomizing the one or more streams of a metal or a metal alloy to form a spray of one or more atomized droplets, guiding the spray of droplets through a nozzle to a rotatable hot body, depositing the droplets to the hot body to form an ingot, controlling the process parameters 1) temperature of the metal or the metal alloy, 2) inlet and outlet pressure of the nozzle, 3) rotation speed of the hot body, and / or 4) distance between the hot body and the spray of droplets, and collecting a metal powder having a predefined particle size distribution, wherein the process parameters are controlled such that the ingot yield is 60% to 80% and the metal powder yield is 40% to 20% respectively relative to the metal source.

Description

Technical Field

[0001] This disclosure relates to methods and systems for producing metal ingots and metal powders from a metal source of metal or metal alloy. Background Technology

[0002] Powder metallurgy is a common feature of many manufacturing technologies in which raw materials in powder form are processed to manufacture various types of components. Examples of these technologies include isostatic pressing, metal additive manufacturing, metal injection molding, powder welding, laser cladding, thermal spraying, and powder sintering.

[0003] Metal powders used in powder metallurgy can be produced by a variety of methods. One of the most common techniques for producing metal powders and pre-alloyed compound powders is gas atomization.

[0004] Gas atomization begins with molten waste metal and involves the interaction between the melt and the atomizing gas. During this process, the impact of the high-energy atomizing gas on the melt flow causes the impact kinetic energy to be transferred from the atomizing gas to the melt, thus producing a fine dispersion of metal droplets.

[0005] One drawback of this method is that the resulting powder has a wide particle size distribution, typically following a Gaussian shape. However, according to powder metallurgy techniques, a narrower particle size distribution may be desirable.

[0006] For example, in powder sintering, fine powders with a narrow particle size distribution are required to achieve high sintering activity, allowing the green body to be sintered to a high density. This means that powder metallurgy processes requiring small particle size and a narrow particle size distribution cannot use powders with larger particle sizes. Powders produced in gas atomization have a wide Gaussian particle size distribution; therefore, gas atomization can generate a high amount of waste powder, indicating low resource utilization efficiency due to energy and raw material waste.

[0007] Furthermore, in newer powder metallurgy technologies such as powder sintering and metal additive manufacturing, narrow and small particle size distribution, sphericity, and smoothness of powders are desirable properties.

[0008] Gas atomization technology is based on atomizing metal into small droplets, which solidify before contacting a surface or each other. However, during gas atomization, many particles containing sufficient latent heat fuse with adjacent particles, forming satellite-shaped or oblate spheroidal particles. The formation of satellite-shaped or oblate spheroidal particles is another drawback of gas atomization, as it is undesirable in the final powder product.

[0009] Although gas atomization dominates in powder metallurgy technologies for powder production, especially in emerging fields such as powder sintering and metal additive manufacturing, there is a great need in powder manufacturing to obtain high-quality metal powders at a lower cost, particularly high yields over a narrower powder range, smaller powder particle size, and enhanced sphericity and smoothness properties, while keeping powder production costs low. Summary of the Invention

[0010] The inventors have realized that the production of one or more metal powders can be achieved in a system including a hot body, similar to spray forming. Therefore, this disclosure relates to the manufacture of metal powders that can then be used in powder metallurgy techniques, such as metal additive manufacturing or powder sintering.

[0011] In spray forming methods, atomized droplets are generated through spray deposition to manufacture bulk materials such as ingots and bars. During the deposition process, droplets containing sufficient latent heat are deposited, while droplets without sufficient latent heat bounce off the hot body. In spray forming methods, these particles that bounce off the hot body are called overspray material and are considered waste. This disclosure also relates to the realization of novel uses for such overspray material, which is considered waste in some conventional manufacturing processes such as spray forming.

[0012] One advantage of the method disclosed herein is the provision of a hot body. It is recognized that in systems in which a hot body (e.g., an ingot) is included in the spray forming process, the deflection of molten metal droplets from the hot body minimizes the formation of satellite-shaped and oversized metal particles.

[0013] Another advantage of the method disclosed herein is that it can achieve a uniform powder particle size distribution, i.e., a narrow particle size distribution. This is a significant advantage compared to conventional metal powder manufacturing techniques that typically provide a wide particle size distribution and large (average) particle size.

[0014] Therefore, this disclosure relates to a method for manufacturing metal powders for powder metallurgy. Metal droplets can be formed, for example, by atomizing a melt or flow of one or more metallic materials. A portion of the atomized droplets is guided and collected on a substrate or hot body, producing a bulk material such as an ingot. Another portion of the atomized droplets bounces off the hot body, producing material in the form of metal powder.

[0015] In a first aspect, this disclosure relates to a method for producing metal ingots and metal powders from a metal source or metal alloy, comprising the following steps:

[0016] - A flow that forms one or more metals or metal alloys from a metal source.

[0017] - A spray that atomizes a stream of one or more metals or metal alloys to form one or more atomized droplets.

[0018] - The spray of droplets is guided through a nozzle to a rotating heated body.

[0019] - Deposit droplets onto a hot body to form an ingot.

[0020] - Control the following process parameters

[0021] ■ The temperature of the metal or metal alloy, and

[0022] ■ The inlet and outlet pressures of the nozzle, and

[0023] ■The rotational speed of the hot body, and

[0024] ■ The distance between the hot body and the spray of droplets makes

[0025] - Collect metal powder with a predefined particle size distribution, wherein process parameters are controlled such that the ingot yield is 60% to 80% relative to the metal source and the metal powder yield is 40% to 20%.

[0026] The interaction between the metal flow and the atomizing unit plays a role in generating droplet arrays of various sizes and the extent to which metal droplets are deposited on a hot body or substrate. Furthermore, the diameter of the metal powder can be varied according to the interaction between the atomized droplets and the hot body. Therefore, an advantage of this disclosure is that, by changing the process parameters, the temperature and diameter of the hot body can be maintained within a predefined range, thus maintaining the bulk-to-metal powder ratio and the size and distribution of the powder particles within a predefined range.

[0027] In conventional spray forming, the ingot is the final product, while oversprayed material is considered waste. Therefore, the spray forming process parameters are selected to maximize the ingot size (relative to the metal source). Typically, in conventional spray forming, approximately 80-85% of the metal source is converted into an ingot. In conventional gas atomization, the final product is metal powder, so process parameters are selected to maximize the amount of metal powder. However, using the method of this disclosure, the final product is both an ingot and metal powder. Therefore, process parameters are selected to provide a suitable amount of high-quality metal powder and an ingot of suitable size, thereby reducing the production costs of both the ingot and the metal powder.

[0028] Preferably, the currently disclosed systems and methods can be configured to control process parameters to obtain a predefined ingot-to-powder ratio. Specifically, in the spray forming process, process parameters can be controlled to reduce ingot yield, thereby increasing the metal powder yield relative to the metal source while providing a fine and uniform metal powder particle size distribution.

[0029] Furthermore, controlling the process parameters can control the powder particle size and distribution, and it is anticipated that the manufactured powder particles can be used in a wide range of powder metallurgy applications.

[0030] Therefore, in a second aspect, this disclosure relates to the use of metal powders in powder metallurgy applications, wherein the metal powders are manufactured by the methods of this disclosure. Thus, this disclosure benefits the functionality of powders previously considered waste.

[0031] Another advantage of the disclosed method is that it provides a bulk material, such as an ingot, and a powder of the same metallic material. In a third aspect, this disclosure relates to a kit manufactured according to the method of this disclosure, the kit comprising a bulk material and a metallic powder. This anticipates that the bulk material and the powder material have the same chemical composition and can be further processed for use as mold or die components in production.

[0032] Therefore, this disclosure can provide a metal powder that can be included in a circular economy for businesses. In industries that use and manufacture metal tools, one challenge is the ability to reuse worn metal parts. By converting them into metal powder via the methods currently disclosed, tools can be reused as raw materials for powder metallurgy applications (e.g., additive manufacturing) and further processed, for example, into tools and machine parts.

[0033] Metal powder production, along with ingot production, can constitute an important circular economy model for many businesses. Another important aspect of this disclosure is that worn steel can be recycled and reused, and new steel can be manufactured in the form of ingots, bars, or near-net-shape bulk materials, as well as metal powder.

[0034] Therefore, spray forming according to this disclosure can create opportunities to support a circular economy by producing metal powders and ingots through the provision of a scrap metal recycling ecosystem. Ingots produced by spray forming can have superior microstructures and offer superior properties compared to cast materials. To date, oversprayed powder generated during ingot manufacturing has generally been considered an unwanted byproduct and subsequently reused. According to the currently disclosed method, the resulting oversprayed powder demonstrates that it consists of spherical particles with excellent flowability required for additive manufacturing (AM) and metal injection molding (MIM) processes. Converting scrap metal into high-quality feedstock powders for AM and MIM, as well as high-quality ingots, could constitute an excellent sustainable business case for spray forming processes.

[0035] This disclosure also relates to a system for producing metal ingots and metal powders, the system comprising:

[0036] - A source of metals or metal alloys,

[0037] - An atomizing unit used to atomize a stream of one or more metals or metal alloys into a spray of one or more atomized droplets.

[0038] - A rotatable hot body configured to receive a spray of droplets guided by a nozzle, such that a portion of the droplets adheres to the hot body to form an ingot, and a portion of the droplets bounces off the hot body and forms powder particles.

[0039] - A grading unit, configured to collect metal powder within a predefined particle size distribution, and

[0040] - Control unit, which is configured to control

[0041] ■ The temperature of the metal or metal alloy, and

[0042] ■ The inlet and outlet pressures of the nozzle, and

[0043] ■The rotational speed of the hot body, and

[0044] ■ The distance between the hot body and the spray of droplets.

[0045] The currently disclosed system is preferably configured to perform the methods described herein.

[0046] The advantage of the disclosed system is that the final metal powder can be processed in a classification unit. Preferably, the classification unit can be configured to manipulate the particle size and Gaussian distribution range of the metal powder, wherein the classification unit may include one or more sieving stations and / or blending stations. The stations may correspond to a first sieving of the metal powder, a second sieving for sorting the metal powder according to particle size, and blending the powder in predetermined proportions according to one or more predefined particle sizes. Attached Figure Description

[0047] The present disclosure will now be described in more detail with reference to the accompanying drawings:

[0048] Figures 1a-1b The principles behind the currently disclosed system for producing metal powders and ingots from a stream of metallic material are shown.

[0049] Figure 2 The particle size distribution of the metal powder produced with and without a heat source is shown.

[0050] Figure 3 The diagram shows the sorting station and the corresponding powder range for particle size.

[0051] Figure 4 The particle size distribution of an exemplary custom powder with at least two distribution ranges is shown.

[0052] Figure 5 An example of the powder morphology of the powder manufactured according to Example 3 is shown.

[0053] Figure 6a An example of a spherical, jet-formed powder is shown.

[0054] Figure 6b An example of spray-formed powder with an irregular shape is shown.

[0055] Figure 7 The flowability of gas-atomized powder and powder manufactured according to the currently disclosed method is shown.

[0056] Figure 8 Examples of kits including ingots and powders and their final products, based on currently disclosed methods, are shown.

[0057] Figure 9 Examples of ingot-based components used in operation and corresponding 1:1 compatible powders for repairing ingot-based components are shown.

[0058] Figure 10 Examples of ingot-based and powder-based components, as well as powders for repairing ingot-based and powder-based components, are shown, wherein in embodiments of this disclosure, the ingots and powders originate from the same production run.

[0059] Figure 11 Examples of the reuse of ingot-based and powder-based components used in operation are shown. Detailed Implementation

[0060] As used herein, the term hot body refers to a body on which atomized metal droplets are continuously deposited at elevated temperatures. For example, in spray forming, atomized metal particles are deposited on a table or substrate to form a hot body. Thus, in spray forming, the hot body continuously expands.

[0061] As used herein, the term ingot refers to the final body material used in the production of products via a spray forming manufacturing process. Atomized droplets of metallic material are deposited onto a hot body to form the final product, a metal ingot.

[0062] As used herein, the terms powder yield and ingot yield refer to the proportion of powder produced relative to the initial metal source and the proportion of ingot produced relative to the initial metal source, respectively.

[0063] In a first aspect, this disclosure relates to a method for producing metal ingots and metal powders from a metal source of a metal or metal alloy. The method includes the step of forming a stream of one or more metals or metal alloys from the metal source. In another embodiment, the stream of one or more metals or metal alloys is atomized by a gas to form a spray of one or more atomized droplets. In another embodiment, the spray of droplets is directed through a nozzle to a rotatable hot body. In one specific embodiment, a portion of the droplets is deposited onto the hot body to form an ingot. The method also includes the step of controlling process parameters. For example, process parameters may be the temperature of the metal or metal alloy, the inlet and outlet pressures of the nozzle, the rotational speed of the hot body, and the distance between the hot body and the spray of droplets. Preferably, the process parameters can be controlled such that the ingot yield is 60% to 80% relative to the metal source, and the metal powder yield is 40% to 20%. In one specific embodiment, the method includes the step of collecting metal powder having a predefined particle size distribution.

[0064] In one embodiment of this disclosure, a portion of the droplets is deposited onto a hot body to form an ingot, and a portion of the droplets forms powder. In another embodiment, at least a portion of the droplets bounces off the hot body and provides contact overspray (COS) metal powder particles. Another portion of the droplets does not contact the hot body and provides non-contact overspray (NCOS).

[0065] In traditional spray forming, approximately 80-85% of the molten metal is deposited to form an ingot. 15-20% of the molten metal is either sent to waste or collected as overspray and remelted for reuse.

[0066] In spray forming processes, powder yield and / or COS / NCOS ratio can vary depending on process parameters. The inventors of this disclosure have observed the influence of process parameters on the properties of the hot body, such as the size of the hot body and the temperature at the top of the hot body.

[0067] Different combinations of hot body size (0.2–0.8 m in diameter) and temperature (1100–1500 °C) can produce different overspray powder particle size and distribution. For example,

[0068] 1) The hot and large bulk results in very fine contact overspray (COS < 100 μm) and low powder yield (< 15%) [COS = 100%, NCOS = 0%].

[0069] 2) The cold and small bulk results in high powder yield (approximately 50%) and large overspray (up to 400 μm) [COS approximately 40-50%, NCOS approximately 50-60%].

[0070] The examples given above demonstrate that a lower powder yield of 15% provides a finer powder particle size of less than 100 μm, while a higher powder yield of 50% is accompanied by a coarser powder particle size of 400 μm and above.

[0071] Therefore, another example could include a powder particle size of up to 300 μm and a powder yield of at least 30% or more, making

[0072] 3) Optimized hot body produces optimized powder yield (30%) and particle size distribution (up to 300 μm) [COS is about 75%, NCOS is about 25%].

[0073] In one embodiment, the process parameters are controlled such that the ingot yield is 60% to 80% relative to the metal source, and the metal powder yield is 20% to 40%. In a preferred embodiment, the process parameters are controlled such that the ingot yield is 68% to 72% relative to the metal source, and the metal powder yield is 28% to 32%.

[0074] In one implementation of the spray forming process, several process variables, such as atomization parameters, chamber parameters, hot body parameters, and melt parameters, are selected to provide a stable spray forming process and increased overspray material.

[0075] Typically, atomizer parameters can affect the shape of the NCOS. Furthermore, the shape of the COS can be influenced by the heating element parameters; therefore, by selecting appropriate parameters, the shape can be controlled.

[0076] Atomization parameters

[0077] It should be mentioned that the atomization parameters can be changed depending on the atomization method. The atomization of molten metal can be in the form of free fall, which allows the molten metal to be released from the bottom of the crucible, forming a flow that travels downward through the atomizer unit until the molten metal is atomized at a certain point below the atomizer unit.

[0078] For example, a stream of molten metal can be atomized by impacting a high-speed inert gas jet. When atomization occurs under a high-speed inert gas, the particle size distribution of the resulting atomized metal powder can vary depending on the type of material used, the gas-to-metal mass flow ratio, and the velocity of the inert gas in the atomization zone. These parameters can influence the pressure of the nozzle spray, through which molten metal is supplied.

[0079] The cross-section of the nozzle can vary to guide and alter the flow of molten metal. This implies that the pressure at the nozzle spray inlet can differ from the pressure at the nozzle spray outlet.

[0080] In a preferred embodiment, the pressure at the nozzle inlet is 2-4 bar, more preferably 3-4 bar. In another preferred embodiment, the pressure at the nozzle outlet is 12-16 bar. However, a further increase in the outlet pressure may reduce the gas-to-metal ratio, thereby resulting in a greater amount of satellite powder.

[0081] Furthermore, the nozzle can be positioned at an angle relative to the horizontal top surface of the hot body. The nozzle angle may depend on the process and ranges from 15° to 90°. In a preferred embodiment, the nozzle angle is 80° to 90°. This allows for the atomized metal or metal alloy to be delivered perpendicularly towards the top surface of the hot body when the angle is 90°.

[0082] Chamber parameters

[0083] Chamber parameters are other process parameters associated with the chamber in which spray forming takes place. The process window for chamber parameters may be relatively narrow, and it is preferable to maintain the following chamber parameters: chamber pressure 1-10 mbar, oxygen: 0-100 ppm, nitrogen >99.9%.

[0084] Melt parameters

[0085] The properties of molten metal materials can be another variable that plays a role in producing ingots and metal powders with predefined yields. For example, some melt parameters can be melt temperature, melt pressure, amount of slag, and melt furnace tilt angle.

[0086] Preferably, the melt pressure can be maintained between 1 and 3 bar. The amount of slag and the melt temperature can be selected according to the metal material, while maintaining the inclination angle of the melt furnace between 30 and 90°. In one embodiment, the temperature of the metal or metal alloy flow is 1500° to 1700°, preferably 1600° to 1700°, and most preferably 1675° to 1685°.

[0087] thermal parameters

[0088] In one embodiment of this disclosure, hot body parameters, including the position of the hot body relative to the nozzle and the velocity of the hot body, are controlled in order to manipulate the powder yield relative to the metal source.

[0089] Advantageously, the distance between the hot body and the sprayed droplets can be from 100 mm to 300 mm. Clearly, when the hot body is closer to the nozzle, more atomized metal droplets can be deposited on the surface of the hot body. As a result, the powder yield may decrease, while the powder particle size becomes finer.

[0090] To increase powder yield, the distance between the hot body and the droplet spray can be increased, thereby increasing COS and NCOS. COS increases significantly, while NCOS increases slightly. The level of increase may depend on other process parameters. Increasing the distance will further produce coarse powder particles larger than 400 μm. Therefore, in a preferred embodiment, the distance between the hot body and the droplet spray is 150 mm to 250 mm.

[0091] In a preferred embodiment, the hot element rotates relative to the nozzle. As the rotational speed increases, the number of atomized particles deposited on the hot element decreases. However, further increases in rotational speed may lead to instability. In one embodiment, the rotational speed of the hot element is from 0.5 rad / s to 10 rad / s, preferably from 0.5 rad / s to 5 rad / s, more preferably from 1.5 rad / s to 3.5 rad / s.

[0092] The advantage of the currently disclosed method is that the hot body can move laterally at a predefined vertical velocity, causing it to move downwards during spray forming. This downward vertical movement offers the advantage of providing an expanded processing area. During deposition, the hot body moves downwards, and ingots with larger dimensions can be formed, such as ingots with greater height.

[0093] Another advantage of the vertical displacement of the hot body is that the distance between the hot body and the nozzle can be maintained within a predefined range, thereby providing a more stable process. In one embodiment, the vertical velocity of the hot body is from 20 mm / min to 200 mm / min, more preferably from 30 mm / min to 150 mm / min, even more preferably from 40 mm / min to 100 mm / min, and most preferably from 60 mm / min to 80 mm / min.

[0094] Traditionally, the process window for providing a stable process is limited. This means that selecting a process variable often requires a limited process window for several other parameters. However, some parameters can be manipulated to allow for greater control over powder yield compared to others.

[0095] For example, the atomization / spray pressure at the nozzle inlet and outlet, the position of the hot body relative to the nozzle spray, and the velocity of the hot body relative to the nozzle can be preferably manipulated. These factors have a greater influence on the size of the hot body and the temperature at the top of the hot body.

[0096] In one embodiment, the temperature of the hot body is 1100°C to 1500°C, preferably 1150°C to 1400°C, more preferably 1150°C to 1250°C, and most preferably 1175°C to 1225°C.

[0097] In another advantageous embodiment, the diameter of the heating element is 0.2m to 0.8m, more preferably 0.3m to 0.7m, even more preferably 0.4m to 0.6m, and most preferably 0.45m to 0.55m.

[0098] Powder particle size

[0099] Optimized process parameters can control the adhesion of molten metal droplets with high latent heat to the hot body. Furthermore, optimized process parameters can control the rebound of molten metal droplets with low latent heat from the hot body, preventing the droplets from merging during their fall; thus, high-quality metal powders with enhanced technical performance are provided.

[0100] The size of the hot body and the temperature at the top of the hot body can affect the amount and particle size distribution of the metal powder, as well as the powder yield. One advantage of the currently disclosed method is that it can provide powder particle sizes below 300 μm, more preferably below 200 μm.

[0101] Another advantage is that the process parameters can be controlled using the currently disclosed method, such that the COS yield is 60% to 75% relative to the metal powder, and the NCOS powder yield is 40% to 25%. In a preferred embodiment, the COS yield is 65% to 70% relative to the metal powder, and therefore the NCOS powder yield is 35% to 30%. The yield can depend on the adhesion of the metal droplets with high latent heat to the hot body.

[0102] The currently disclosed methods can provide predefined powder particle size distributions, and for some applications, a combination of powder particle sizes may be desired.

[0103] Screening

[0104] The advantage of the currently disclosed method is that NCOS and COS powders can be collected as metal powders and graded according to industrial applications for further use.

[0105] In one implementation, the classification unit can collect metal powder. One advantage of the classification unit is that it can obtain powder particles within a predefined particle size distribution. Classification can be achieved through mechanical separation processes such as sieving, flotation, vibratory separation, filtration, centrifugation, etc. Advantageously, flattened and satellite-shaped metal particles can be filtered out.

[0106] In one embodiment, metal powder is sorted to obtain one or more predefined powder particle size distributions. The powder particle size distribution may be selected from the group consisting of: 0-25 μm, 25-50 μm, 50-75 μm, 75-100 μm, 100-125 μm, 125-150 μm, 150-175 μm, 175-200 μm, 200-225 μm, 225-250 μm, 250-275 μm, and 275-300 μm. This feature anticipates that at least one powder particle size distribution range can be separated from at least a second powder particle size distribution range.

[0107] It may be desirable to combine different particle size ranges in different percentages to enhance the process and the final product. For example, a combination of two or more powder particle size ranges can increase the density of the final product in powder sintering. In another embodiment, metal powders are blended such that metal powder of at least one powder particle size distribution range is blended with metal powder of at least a second powder particle size distribution range.

[0108] application

[0109] In one embodiment, the metal powder is used in powder metallurgy applications, such as metal additive manufacturing and / or powder sintering, wherein the metal powder is manufactured by the methods currently disclosed. Therefore, the methods of this disclosure may be suitable for manufacturing metal products using metal powder metallurgy methods such as additive manufacturing or powder sintering, wherein the metal powder is manufactured according to the methods currently disclosed.

[0110] The inventors have recognized that powders are particularly well-suited for additive manufacturing (rapid manufacturing / prototyping (RM / P) or 3D printing), such as selective laser sintering (SLS), selective laser melting (SLM), and 3D laser cladding. The inventors have further achieved enhanced properties of the powders, such as apparent and sintering density, flowability, sinterability, and compressibility, for applications in additive manufacturing and powder sintering technologies. Especially in additive manufacturing, the surface roughness of the finished part is primarily influenced by the powder particle size; therefore, smaller particle sizes can promote higher surface quality.

[0111] Therefore, for applications where surface roughness is critical, it may be particularly advantageous to use the powders of this disclosure, which typically have a minimum particle size of less than 300 μm.

[0112] Furthermore, laser, plasma, or electron beam welding can be performed using powders or wires produced by the methods disclosed herein. Other powder metallurgy techniques for producing metal powders according to this disclosure include powder metal injection molding, powder welding, thermal spraying, cold spraying, and spray forming.

[0113] Advantageously, a portion of the molten metal can be deposited onto the hot body to form a near-net-shape solid. This near-net-shape solid, or ingot, can be the bulk material, commercially typically a billet, ring, tubular product, and various other products. Depending on the application, the bulk material can be used in an as-deposited state, or it can be processed post-deposit.

[0114] This disclosure also relates to a kit comprising a bulk material derived from an ingot and metal powder, wherein the bulk material and metal powder are manufactured using the methods currently disclosed. Deposition of metal droplets forms an ingot, while undeposited metal droplets can be collected and graded into various ranges of metal powder.

[0115] Therefore, one advantage of this disclosure is that it provides a kit comprising body material, particularly and preferably metal powder derived from the same production process, which is otherwise considered waste.

[0116] Preferably, a kit can be provided for one or more metal casting molds or die components. The kit may include at least one ingot and metal powder, wherein the ingot and metal powder originate from the same material source and are manufactured simultaneously in the same manufacturing process. One advantage of this kit may be that it opens up the possibility of obtaining materials in both ingot and powder form, produced in the same process and supplied by a single vendor.

[0117] In tool manufacturing, tool, mold, or die components are manufactured using different processes, such as forming, subtractive manufacturing, or additive manufacturing. The manufacturing process is determined based on the desired final performance of the component, cost and material savings, and other factors. After the manufacturing process is determined, raw materials are obtained. The form of raw materials may vary depending on the process, indicating that raw materials can be obtained through different processes. One disadvantage of using raw materials derived from different process technologies is that the material composition may differ. Even slight differences in the material composition between tool components can lead to challenges in production, such as tool component breakage.

[0118] One of the main advantages of the currently disclosed kit is that it provides both bulk and powder materials with the same material composition, suitable for processing using conventional manufacturing techniques and powder metallurgy. Conventional manufacturing techniques can be a variety of manufacturing methods used and accepted by many users in the manufacturing industry. This means that the kit offers flexibility in the choice of manufacturing processes for tool parts, molds, and dies.

[0119] Therefore, this disclosure also relates to a metal product or a tool in the form of a casting or mold. In another advantageous embodiment, at least a first portion of the casting or mold is manufactured by at least one conventional manufacturing method. The conventional manufacturing method may be a conventional subtractive manufacturing technique, such as milling or drilling, or it may be a forming process, preferably a bulk forming process, such as forging or rolling. Alternatively, the bulk material may be provided and used as produced. Furthermore, at least a second portion of the casting or mold is manufactured by powder metallurgy technology (e.g., additive manufacturing), wherein the first and second portions are made of the same metal or alloy and originate from a manufacturing process according to the method disclosed herein.

[0120] In another embodiment, at least a first portion of the product is obtained by subtractive manufacturing of an ingot, and at least a second portion of the product is manufactured by additive deposition of powder onto the first portion of the product, wherein the ingot and powder are manufactured according to the method of this disclosure such that the ingot and powder originate from the same production run and are 1:1 compatible. Therefore, a single product can be manufactured from multiple starting state components (e.g., body and powder) and through multiple manufacturing processes (e.g., machining and AM); thus, the physical and mechanical properties of the product can be controlled and enhanced.

[0121] system

[0122] Furthermore, this disclosure relates to a system for producing metal ingots and metal powders. The system includes a source of metal or metal alloy, an atomizing unit for gas atomizing a stream of one or more metals or metal alloys, and a rotatable hot body. The system is configured such that a spray forming one or more atomized droplets is directed through a nozzle to a hot body suitable for receiving the droplets. In one embodiment, a portion of the droplets adheres to the hot body, for example, deposited onto the hot body to form an ingot, and a portion of the droplets bounces off the hot body to form powder particles.

[0123] The system also includes a grading unit and a control unit, the grading unit being configured to collect metal powder within a predefined particle size distribution. The control unit can be configured to control parameters such as the temperature of the metal or metal alloy, the inlet and outlet pressures of the nozzle, the rotational speed of the hot body, and the distance between the hot body and the sprayed droplets.

[0124] In one embodiment, the system further includes a control system. For example, the control system could be an image processing control system that captures high-speed camera images of the hot body. Preferably, the control system can change process variables to control the size and temperature of the hot body. An alternative to this control system could be an AI system. This means that the initially defined temperature and size of the hot body can be controlled using real-time, actual measurements of its temperature and size, such that the selected or defined process parameters are changed by the AI ​​system. It should be noted that the system is preferably configured to perform the methods disclosed herein.

[0125] In one embodiment, the size of the metal powder is measured during spray forming, allowing a predefined metal powder particle size distribution to be achieved by controlling process parameters. This measurement can be performed using a laser-based sensor. Therefore, the system can be configured to optimize production yield by identifying oversprayed particles during spray forming using a laser-based sensor. Overspray can preferably solidify when it reaches the bottom of the spray forming chamber, and the measured particle size can be used as a standard for changing process parameters until a suitable particle size distribution is obtained.

[0126] In one embodiment, the diameter of the hot body is measured during spray forming, allowing a predefined diameter to be achieved by controlling process parameters. Measuring the diameter of the hot body during the process can advantageously optimize powder yield. Preferably, at least one thermal imager can be provided to acquire images of the hot body. Specifically, the acquired images can be corrected via a calibration frame using algorithms for machine vision to define the actual diameter of the hot body. Process parameters can then be adjusted until the predefined hot body size is achieved.

[0127] Detailed description of the attached figures

[0128] The present disclosure will now be described more fully below with reference to the accompanying exemplary embodiments shown in the accompanying drawings, where applicable. However, it should be noted that the systems and methods disclosed herein can be embodied in various forms. The embodiments provided herein are intended to illustrate the full and complete disclosure. Therefore, the embodiments set forth herein should not be construed as limiting, but rather as a tool to convey the scope of this disclosure to those skilled in the art. Throughout the document, the same reference numerals refer to the same elements.

[0129] Figure 1aAn embodiment of a currently disclosed spray forming system for producing metal ingots and metal powders is shown. A flow 1 of metal or molten metal is provided through a nozzle having an inlet 2 and an outlet 3, and the molten metal source is sequentially atomized into a spray of fine droplets 11. The nozzle outlet 3 is positioned directly above the top surface 4' of a hot body 4, spraying substantially along and above said top surface 4'. The metal droplets 11 are deposited on the hot body 4 at an elevated temperature. The consolidation of the droplets is primarily determined by the nature of the spray and the thermal state of the droplets, such that droplets 11' with larger particle size and high latent heat are deposited on the hot body 4, while smaller droplets 11" with lower latent heat bounce off the hot body.

[0130] Figure 1b Another embodiment of the currently disclosed spray forming system for producing metal ingots and metal powders is shown. The process is arranged such that the nozzle outlet 3 is positioned such that atomized metal droplets are guided onto a substrate or hot body 4 at a relative angle β relative to the top surface 4' of the hot body. As the substrate rotates, the droplets solidify on the substrate to form an ingot. As deposition continues, the hot body moves downwards, thus providing flexibility in forming ingots of various sizes.

[0131] Similar to Figure 1a As shown, droplets impact the substrate under semi-solid conditions, thereby depositing metal droplets (typically larger droplets) with a sufficient liquid-to-solid ratio, while droplets with a higher solids fraction (typically smaller droplets) form powder particles. Droplets that encounter the hot body but do not adhere to it are referred to as contact overspray (COS) 31. Metal droplets 11 do not interact with the hot body and are therefore similar to powder 11 atomized by gas, and are referred to as non-contact overspray (NCOS) 21. In one respect, since larger powder particles are deposited on the hot body 4, the hot body 4 acts as a thermal filter.

[0132] Figure 2 An example of particle size distribution of metal powders produced with and without a hot body is shown. In conventional powder production techniques (such as gas atomization), particle size can vary up to 1000 μm, while when a gas atomization unit is used in conjunction with a hot body, the particle size decreases to a maximum of 250 μm. This is because larger particles are deposited on the hot body, such as… Figure 1a and Figure 1b As shown.

[0133] Figure 3An exemplary illustration of a sorting station is shown. In an advantageous embodiment of the spray forming system according to this disclosure, such a sorting station can be provided. The station shown includes a three-stage filtration system for sorting metal powders in three ranges: range 1, range 2, and range 3. First, coarser powders with a particle size distribution of 75-200 μm are sorted and classified into range 3. Powder particles with a particle size of 25-100 μm are sorted by a second station and classified into range 2. Some powders larger than 75 μm that were not sorted in the first sorting station are also classified into range 2. Finally, powder particles smaller than 50 μm, mostly smaller than 25 μm, are classified into range 1.

[0134] Figure 4 This is an example of a custom powder with at least two powder particle size ranges. AM powder 1 is a combination of range 1 and range 2 powders. This combination can be in various percentages. In one example, AM powder 1 corresponds to a combination of 80% range 1 powder and 20% range 2 powder. AM powder 2 is a combination of range 1, range 2, and range 3 powders. In one example, AM powder 2 is a combination of 10% range 1 powder, 55% range 2 powder, and 35% range 3 powder. Combinations of different ranges at a given percentage can be defined according to the process in which the powder particles will be used.

[0135] Example

[0136] This disclosure will now be described with reference to embodiments.

[0137] Powder Yield Definition

[0138] Atomization parameters: pressure at the nozzle inlet is 3 bar to 4 bar, and pressure at the nozzle outlet is 12 bar to 16 bar.

[0139] Hot body parameters: The position of the top of the hot body relative to the spray is 150 mm to 250 mm, the rotation speed of the hot body is 1.5 rad / s to 3.5 rad / s, and the downward movement speed of the hot body is 70 mm / min.

[0140] Melt parameters: melt temperature is 1680℃, melt furnace tilt angle is 80-90°.

[0141] The target melt temperature is 1200°C, and the target ingot diameter is 0.46 m. ​​This is smaller and cooler than typical spray forming with optimized ingot volume, where a hot body with a diameter of 0.5 m is maintained at approximately 1330°C. This will reduce the ingot yield from approximately 80% to approximately 70% and increase the powder yield from approximately 20% to approximately 30%.

[0142] Parameter control

[0143] Example 1

[0144] If the hot body size is 0.5m and the temperature is 1300℃, the speed increases from 60mm / min until the real-time AI system measures a size of 0.46m in diameter, which is expected to occur at a speed of approximately 70mm / min.

[0145] Example 2

[0146] If the hot body size is 0.5m and the temperature is 1300℃, the atomization pressure at the outlet is increased from 12 bar to 16 bar while maintaining a speed of 60 mm / min.

[0147] Furthermore, to demonstrate the effect of process parameters on the quality of metal powder obtained by the spray forming method disclosed herein, two experiments (Example 3 and Example 4) have been conducted. The process parameters and experimental results will be discussed below.

[0148] Example 3

[0149] The publicly disclosed spray forming process has been operating under the following conditions:

[0150] - Atomizer inlet pressure: 2-2.5 bar

[0151] - Vertical retraction speed of ingot: 42-50 mm / min.

[0152] -Ingot rotation speed: 6.3 rad / s.

[0153] Process measurement:

[0154] - Temperature at the top of the hot body: 1250℃, wherein the hot body is a cylindrical ingot with a uniform diameter of 510mm.

[0155] Example 4

[0156] To produce finer and more spherical powders, the process parameters of the disclosed spray forming method are as follows:

[0157] - Atomizer inlet pressure: 2-2.5 bar

[0158] - Vertical retraction speed of ingot: 56-66 mm / min.

[0159] -Ingot rotation speed: 6.3 rad / s.

[0160] Process measurement:

[0161] - Temperature at the top of the hot body: 1350℃, wherein the hot body is a cylindrical ingot with a uniform diameter of 500mm.

[0162] Compared to Example 4, Example 3 was conducted at a lower ingot top temperature (1250°C) while maintaining a (larger) ingot diameter (510 mm), a (lower) vertical retraction speed (42-50 mm / min), and a (lower) secondary atomizer pressure (6 bar). In both experiments, the primary atomizer and rotation speed were kept constant.

[0163] Laser diffraction measurements were coupled with X-ray CT scans and scanning electron microscopy to determine the particle size distribution and powder morphology (measured here as sphericity) of Examples 3 and 4.

[0164] Generally, spray-formed powders can be divided into two types: such as Figure 6a The spherical shape shown and as Figure 6b The irregular shape shown.

[0165] Example powder morphology of Example 3 is as follows Figure 5 As shown. Example 3 produced a relatively coarse particle size distribution. In Example 3, when a sphericity threshold greater than 0.9 was used, approximately 70% of the particles were classified as spherical.

[0166] According to this disclosure, the process parameters used in Example 4 (as described above) result in a higher amount of non-contact overspray powder (NCOS) in a small particle size range (0-60 μm), while reducing contact overspray powder (COS) in a larger particle size range (>60 μm).

[0167] As measured from a normal / Gaussian distribution, Example 4 produced a finer particle size distribution that was on average about 20% lower than that of Example 3, while maintaining better particle morphology. In Example 4, more than 85% of the particles were classified as spherical, indicating an improvement in powder size and shape compared to Example 3.

[0168] The optimized powder from Example 4 was sieved into various particle size distributions and compared with powders obtained through different commercially available processes for manufacturing spherical powders (referred to as gas atomization). Figure 7 The flowability of the optimized powder (T15) from Example 4 was compared with that of a commercially available powder (316L). The flowability of the powder was measured using a Hall effect flowmeter according to ASTM B213-20. Figure 7 As shown, the optimized powder typically flows faster, indicating improved flowability. In this embodiment, the flowability of particles with a size of 25-62 μm was improved.

[0169] When compared to commercially available powders used in additive manufacturing, powders manufactured according to this disclosure typically exhibit better flowability due to their higher average sphericity and better morphology. The improvements in particle size and shape described above can lead to improvements in powder functionality, such as through better flowability, which is crucial for several manufacturing processes such as laser powder bed fusion, electron beam powder bed fusion, laser cladding, and directed energy deposition.

[0170] Based on the publicly available experiments, it can be concluded that hot materials, such as ingots, can play a crucial role in powder morphology. Furthermore, the process parameters of the disclosed spray forming method can provide control over the generated powder.

[0171] kit

[0172] The body material and metal powder manufactured according to this disclosure can be used as components in a variety of ways. At least a first part of the product can be obtained by subtractive manufacturing, such as machining of an ingot. Figure 8 An example of an assembly made from a jet forming (SF) ingot and further processed by a machining process is shown. SF powder, i.e., powder manufactured according to this disclosure, can be used to deposit material in an additive manner, commonly referred to as additive manufacturing (AM) or 3D printing, to build on top of the manufactured assembly. Thus, at least a second portion of the product can be manufactured by additive deposition of powder on a machined ingot, wherein the ingot and powder are manufactured according to the method of this disclosure, and the ingot and powder come from the same production run and are 1:1 compatible. By combining subtractive and additive manufacturing methods to manufacture a single product, control over product properties, such as mechanical properties, is enhanced.

[0173] Figure 9 This is an exemplary application of the kit, in which one component is made from an SF ingot and further put into operation (as schematically shown by three gears; their shape, number, and size are not limited). At the end of its normal service life, the component is repaired using 1:1 compatible powder from the same production run. Using such a repair cycle, the component can be reused multiple times.

[0174] Figure 10 This is an exemplary application of the kit, in which one component is made from AM of SF ingots and SF powder from the same production run and put into operation. It is related to... Figure 9The difference shown is that the products put into operation are made from ingots and powder from the same spray forming run. At the end of their service life, the components are repaired using 1:1 compatible powder from the same production run. In addition to repairing the parts to their previous state, the 1:1 compatible powder can be used to further process the components via AM (Advanced Processing) to optimize and / or change external dimensions, mechanical properties, etc. Using this cycle, the components can be reused multiple times.

[0175] Figure 11 This is an exemplary application of the kit, in which one component is made from SF ingots or from the same running SF ingots + SF powder and put into operation. At the end of its service life, the component is repaired and reused multiple times. Once the cycle of repair and reuse is complete (due to the use of all 1:1 compatible SF powders), the component is reused through the same SF process, producing new ingots + powder, thus creating a circular ecosystem.

[0176] project

[0177] 1. A spray forming method for producing metal ingots and metal powders from a metal source or metal alloy, comprising the following steps:

[0178] - A flow that forms one or more metals or metal alloys from a metal source.

[0179] - A spray that atomizes a stream of one or more metals or metal alloys to form one or more atomized droplets.

[0180] - The spray of the droplets is guided through a nozzle to a rotatable heated body.

[0181] - The droplets are deposited onto the hot body to form the ingot.

[0182] - Control the following process parameters: 1) the temperature of the metal or metal alloy, 2) the inlet and outlet pressures of the nozzle, 3) the rotational speed of the hot body, and / or 4) the distance between the hot body and the spray of the droplets, and

[0183] - Collect metal powders with a predefined particle size distribution.

[0184] The process parameters are controlled such that, relative to the metal source, the ingot yield is 60% to 80% and the metal powder yield is 40% to 20%, respectively.

[0185] 2. The method according to Project 1, wherein the method includes providing metal powder particles such that a portion of the droplets bouncing off the hot body provides contact overspray (COS) metal powder particles, and another portion of the droplets not in contact with the hot body provides non-contact overspray (NCOS).

[0186] 3. The method according to any one of the preceding items, wherein the process parameters are controlled such that the ingot yield is 60% to 80% relative to the metal source, and the metal powder yield is 20% to 40%.

[0187] 4. The method according to any one of the preceding items, wherein the process parameters are controlled such that the ingot yield is 68% to 72% relative to the metal source, and the metal powder yield is 28% to 32%.

[0188] 5. The method according to any one of the preceding items, wherein the temperature of the flow of the metal or metal alloy is 1500°C to 1700°C, preferably 1600°C to 1700°C, and most preferably 1675°C to 1685°C.

[0189] 6. The method according to any one of the preceding items, wherein the pressure at the nozzle inlet is 2 bar to 4 bar, more preferably 3 bar to 4 bar.

[0190] 7. The method according to any one of the preceding items, wherein the pressure at the nozzle outlet is preferably 12 bar to 16 bar.

[0191] 8. The method according to any one of the preceding items, wherein the rotational speed of the heated body is from 0.5 rad / s to 10 rad / s, preferably from 0.5 rad / s to 5 rad / s, more preferably from 1.5 rad / s to 3.5 rad / s.

[0192] 9. The method according to any one of the preceding items, wherein the distance between the heat source and the spray of the droplets is 100 mm to 300 mm, preferably 150 mm to 250 mm.

[0193] 10. The method according to any one of the preceding items, wherein the temperature of the heated body is 1100°C to 1500°C, preferably 1150°C to 1400°C, more preferably 1150°C to 1250°C, and most preferably 1175°C to 1225°C.

[0194] 11. The method according to any one of the preceding items, wherein the diameter of the heating element is 0.2m to 0.8m, more preferably 0.3m to 0.7m, even more preferably 0.4m to 0.6m, and most preferably 0.45m to 0.55m.

[0195] 12. The method according to any one of the preceding items, wherein the provided powder has a particle size of less than 300 μm, more preferably less than 200 μm.

[0196] 13. The method according to any one of items 2-12 above, wherein the process parameters are controlled such that the COS yield is 60% to 75% relative to the metal powder, and the NCOS powder yield is 40% to 25%.

[0197] 14. The method according to any one of items 2-10 above, wherein the process parameters are controlled such that the COS yield is 65% to 70% relative to the metal powder, and the NCOS powder yield is 35% to 30%.

[0198] 15. The method according to any one of the preceding items, comprising the step of moving the hot body laterally at a predefined vertical speed, such that the hot body moves downward during spray forming.

[0199] 16. The method according to item 15, wherein the vertical velocity of the hot body is 20 mm / min to 200 mm / min, more preferably 30 mm / min to 150 mm / min, even more preferably 40 mm / min to 100 mm / min, and most preferably 60 mm / min to 80 mm / min.

[0200] 17. The method according to any one of the preceding items, comprising the step of sorting the metal powder to obtain one or more predefined powder particle size distributions.

[0201] 18. The method according to any one of the preceding items, wherein the powder particle size distribution is selected from the group consisting of: 0-25 μm, 25-50 μm, 50-75 μm, 75-100 μm, 100-125 μm, 125-150 μm, 150-175 μm, 175-200 μm, 200-225 μm, 225-250 μm, 250-275 μm and 275-300 μm.

[0202] 19. The method according to any one of the preceding items, comprising the step of blending at least one metal powder with a powder particle size distribution with at least a second metal powder with a powder particle size distribution.

[0203] 20. The method according to any one of the preceding items, further comprising the step of measuring the size of the metal powder during spray forming and accordingly controlling the process parameters to control the particle size distribution of the metal powder.

[0204] 21. The method according to any one of the preceding items further includes the step of measuring the diameter of the hot body during spray forming and controlling the process parameters accordingly to control the diameter of the hot body.

[0205] 22. A method for manufacturing metal products using metal powder metallurgy, wherein the metal powder is manufactured according to any one of items 1-21.

[0206] 23. Use of metal powder in powder metallurgy applications, wherein the metal powder is manufactured by any one of items 1-21.

[0207] 24. A method for manufacturing a metal product using metal powder metallurgy methods such as additive manufacturing or powder sintering, wherein the metal powder is manufactured by the method according to any one of items 1-21.

[0208] 25. A kit comprising a bulk material and metal powder, manufactured by a method according to any one of items 1-21, wherein the bulk material is derived from the ingot and has a 1:1 material compatibility.

[0209] 26. A kit for one or more metal casting molds or mold components, comprising at least one ingot and metal powder, wherein the ingot and metal powder have the same material composition, and wherein the ingot and metal powder are manufactured by the method according to any one of items 1-21.

[0210] 27. A kit for one or more metal casting molds or mold components, comprising an ingot and powder, wherein the ingot and the powder are derived from the same material source and are manufactured simultaneously in the same manufacturing process according to any one of items 1-21.

[0211] 28. A metal product in the form of a mold or die, wherein at least a first portion of the mold or die is manufactured by at least one conventional manufacturing method, such as subtractive manufacturing, and at least a second portion of the mold or die is manufactured by a powder metallurgy method, such as additive manufacturing, wherein the first portion and the second portion are made of the same metal or alloy and originate from a manufacturing process according to any one of items 1-21.

[0212] 29. A metal product, wherein at least a first portion of the product is obtained from the subtractive manufacturing of an ingot, and at least a second portion of the product is manufactured by additive deposition of powder on the first portion of the product, wherein the ingot and the powder are manufactured according to any one of items 1-21, such that the ingot and the powder originate from the same production run and are 1:1 compatible.

[0213] 30. A spray forming system for producing metal ingots and metal powders, comprising:

[0214] - A source of metals or metal alloys,

[0215] - An atomizing unit used to atomize a stream of one or more metals or metal alloys into a spray of one or more atomized droplets.

[0216] - A rotatable hot body configured to receive a spray of droplets guided by a nozzle, such that a portion of the droplets adheres to the hot body to form the ingot, and a portion of the droplets bounces off the hot body and forms powder particles.

[0217] - A grading unit, configured to collect metal powder within a predefined particle size distribution, and

[0218] - A control unit configured to control 1) the temperature of the metal or metal alloy, 2) the inlet and outlet pressures of the nozzle, 3) the rotational speed of the hot body, and 4) the distance between the hot body and the spray of the droplets.

[0219] 31. The system according to item 30, wherein the system grading unit further includes a sorting station configured to sort the metal powder according to at least one or more powder sizes.

[0220] 32. The system according to items 30-31, wherein the grading unit further includes a blending station configured to blend metal powder of at least one powder size with at least a second powder size.

[0221] 33. The system according to any one of the preceding items, wherein the system is configured to perform the method according to any one of items 1-21.

Claims

1. A spray forming method for producing metal ingots and metal powders from a metal source or metal alloy, comprising the following steps: - A flow that forms one or more metals or metal alloys from a metal source. - A spray that atomizes a stream of one or more metals or metal alloys to form one or more atomized droplets. - The spray of the droplets is guided through a nozzle to a rotatable heated body. - The droplets are deposited onto the hot body to form the ingot. - Control the following process parameters: 1) the temperature of the metal or metal alloy, 2) the inlet and outlet pressures of the nozzle, 3) the rotational speed of the hot body, and / or 4) the distance between the hot body and the spray of the droplets, and - Collect metal powders with a predefined particle size distribution. The process parameters are controlled such that, relative to the metal source, the ingot yield is 60% to 80% and the metal powder yield is 40% to 20%.

2. The method of claim 1, wherein the method comprises providing metal powder particles such that a portion of the droplets bouncing off the hot body provides contact overspray (COS) metal powder particles, and another portion of the droplets not in contact with the hot body provides non-contact overspray (NCOS), and wherein the process parameters are controlled such that the COS yield is 65% to 70% relative to the metal powder, and the NCOS powder yield is 35% to 30%.

3. The method according to any one of the preceding claims, wherein the process parameters are controlled such that the ingot yield is 60% to 80% relative to the metal source, and the metal powder yield is 20% to 40%.

4. The method according to any one of the preceding claims, wherein the process parameters are controlled such that the ingot yield is 68% to 72% relative to the metal source, and the metal powder yield is 28% to 32%.

5. The method according to any one of the preceding claims, wherein the pressure at the nozzle inlet is 3 bar to 4 bar, and the pressure at the nozzle outlet is 12 bar to 16 bar.

6. The method according to any one of the preceding claims, wherein the rotational speed of the heated body is from 0.5 rad / s to 10 rad / s.

7. The method according to any one of the preceding claims, wherein the temperature of the heated body is 1175°C to 1225°C.

8. The method according to any one of the preceding claims, wherein the distance between the heat source and the spray of the droplets is 150 mm to 250 mm.

9. The method according to any one of the preceding claims, wherein the diameter of the heating element is 0.45 m to 0.55 m.

10. The method according to any one of the preceding claims, wherein the process parameters are controlled such that the COS yield is 60% to 75% relative to the metal powder, and the NCOS powder yield is 40% to 25%.

11. The method according to any one of the preceding claims, wherein the provided powder has a particle size of less than 200 µm.

12. The method according to any one of the preceding claims, comprising the step of moving the hot body laterally at a predefined vertical speed such that the hot body moves downward during spray forming, wherein the vertical speed of the hot body is 60 mm / min to 80 mm / min.

13. The method according to any one of the preceding claims, comprising the step of sorting the metal powder to obtain one or more predefined powder particle size distributions, wherein the powder particle size distribution is selected from the group consisting of: 0-25 µm, 25-50 µm, 50-75 µm, 75-100 µm, 100-125 µm, 125-150 µm, 150-175 µm, and 175-200 µm.

14. A method for manufacturing metal products using metal powder metallurgy, wherein the metal powder is manufactured by the method according to any one of claims 1-13.

15. A kit comprising a bulk material and metal powder, manufactured by the method according to any one of claims 1-13, wherein the bulk material is derived from the ingot and has a 1:1 material compatibility.

16. A kit for one or more metal casting molds or mold components, comprising an ingot and powder, wherein the ingot and the powder are derived from the same material source and are manufactured simultaneously in the same manufacturing process according to any one of claims 1-13.

17. A metal product in the form of a mold or die, wherein at least a first portion of the mold or die is manufactured by at least one subtractive manufacturing method, and at least a second portion of the mold or die is manufactured by powder metallurgy, wherein the first portion and the second portion are made of the same metal or alloy and are derived from a manufacturing process according to any one of claims 1-13.

18. The metal product in the form of a casting or mold according to claim 17, wherein the powder metallurgy method is additive manufacturing.

19. A metal product, wherein at least a first portion of the product is obtained from the subtractive manufacturing of an ingot, and at least a second portion of the product is manufactured by additive deposition of powder on the first portion of the product, wherein the ingot and the powder are manufactured by the method according to any one of claims 1-13 such that the ingot and the powder originate from the same production run and are 1:1 compatible.

20. A spray forming system for producing metal ingots and metal powders, comprising: - A source of metals or metal alloys. - An atomizing unit for atomizing a stream of one or more metals or metal alloys into a spray of one or more atomized droplets. - A rotatable hot body configured to receive a spray of droplets guided by a nozzle, such that a portion of the droplets adheres to the hot body to form the ingot, and a portion of the droplets bounces off the hot body and forms powder particles. - A grading unit, configured to collect metal powder within a predefined particle size distribution, and - A control unit configured to control 1) the temperature of the metal or metal alloy, 2) the inlet and outlet pressures of the nozzle, 3) the rotational speed of the hot body, and 4) the distance between the hot body and the spray of the droplets. The system is configured to perform the method according to any one of claims 1-13.

21. The system of claim 20, wherein the grading unit further comprises a sorting station and a blending station, the sorting station being configured to sort metal powders according to at least one or more powder sizes, and the blending station being configured to blend metal powders of at least one powder size with at least a second powder size.

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