A novel gas atomized catalyst powder and its preparation process

Abstract

The present invention discloses a novel gas atomized catalyst powder and its preparation process. The preparation process is as follows: Step 1: Raw material preparation: The raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, and Fe. Step 2: Melting: Place the raw materials in an intermediate frequency induction furnace for melting. Step 3: Atomization: After melting and reaching the preset superheat degree, pour the obtained alloy liquid into the tundish to start atomization. The beneficial effects of the present invention are: It is not necessary to use rare earth metals, reducing the production cost of metal powders; the atomized metal powders are solidified and settled in the atomization tower; the settled metal powders fall into the powder collection tank for recycling, improving the powder recycling utilization rate; the prepared catalyst powder has a narrow particle size distribution and a high spherical slope, facilitating the control of the width of the powder particle size distribution.

Description

Technical Field

[0001] The present invention belongs to the technical field of catalyst powder, and particularly relates to a novel gas atomized catalyst powder and a preparation process thereof. Background Art

[0002] As a key raw material for additive manufacturing, the quality of metal powder largely determines the final quality of the product; with the rapid development of additive manufacturing technology and its process particularity, the quality requirements for metal powder are getting higher and higher, such as high sphericity, good fluidity, low gas and impurity content, etc.; at the same time, with the continuous expansion of the application fields of additive manufacturing, more and more types of metal powder are needed; currently, the methods for preparing metal powder mainly include atomization method, mechanical pulverization method, rotating electrode method, electro-chemical corrosion method, reduction method, etc.; among them, only gas atomization method (GA) and plasma rotating electrode method (PREP) can directly produce spherical powder, while other methods need additional treatment to obtain near-spherical powder; the powder prepared by PREP has a relatively high sphericity, but due to the limitation of the process principle, the fine powder yield is relatively low, and it is mainly used for preparing powder for powder feeding additive manufacturing; the powder prepared by gas atomization powder technology has the advantages of high sphericity, good fluidity, low O, N, H content, etc., and a large adjustable range of powder particle size distribution, etc., and has become the main method for producing high-performance spherical metal powder.

[0003] Catalyst powder, that is, pre-alloy powder, is a metal-based composite powder composed of metals such as Fe-based, Ni-based, Mn, and Cr. The alloy particles are made of two or more different materials, and it is generally divided into basic pre-alloy powder and professional pre-alloy powder; catalyst powder mainly has two categories of iron-based and nickel-based materials, which solves the problem of a large amount of use of scarce precious metals and greatly reduces the production cost.

[0004] There are many types of raw materials for catalyst powder, and the product types are also diverse. However, due to the differences in the main raw material components and the production process difficulties, there are certain differences in the product prices. Among them, Fe-Cu type, Cu-Sn, and Fe-Ni type basic powders are widely used, there are many production enterprises, and the prices are relatively cheap; the production enterprises of Fe-Cu-Ni-Sn type, Fe-Cu-Co-Sn type, and Fe-Cu-Co type multi-element pre-alloy powders are few, the technical content is higher, so the product prices are also higher, and the market share is relatively low; with the continuous growth of market demand and the increasing support of national policies for catalyst powder and its downstream industries, the attraction of the catalyst powder industry to capital is continuously enhanced, the number of production enterprises in the catalyst powder industry is gradually increasing, and the industry production capacity scale is continuously expanding; however, due to the certain technical barriers, customer barriers and the development characteristics of industrial chain integration in the catalyst powder industry, the number of existing enterprises in the industry is not large, and the key enterprises in the industry occupy most of the market share.

[0005] Gas atomization technology is an important method for preparing high-performance metals and has extensive applications in the production of powdered catalysts, especially in the production of powdered catalysts for synthesizing high-grade diamond. The basic principle of gas atomization technology is that high-speed and high-pressure gas flow generated by an atomization nozzle pulverizes the metal melt into fine droplets, which then become metal powders through spheroidization, cooling, and solidification. Due to the high cooling rate of the molten droplets after atomization and pulverization, the prepared powders usually have the tissue characteristics of rapid solidification, such as fine grains, less or no segregation, and high solid solubility. Compared with water atomization, the catalyst powder prepared by gas atomization technology has the advantages of high sphericity and low oxygen content.

[0006] A catalyst powder for synthesizing self-sharpening diamond and its preparation method with the publication number of CN116037147A. This patent discloses that, calculated by mass percentage, it includes the following components: 29.5 - 30.2% Ni, 0.03 - 0.05% Co, 0.03 - 0.05% Ca, 0.03 - 0.05% Mn, 0.03 - 0.05% Al, 0.028 - 0.035% Mg, 0.028 - 0.035% Cu, 0.05% rare earth metal, and the balance is Fe. It includes the following steps: According to the raw material composition of a catalyst powder for synthesizing self-sharpening diamond, weigh each component by weight; put each component into an intermediate frequency heating furnace and carry out melting under argon protection. The melting temperature is 1450 - 1500 °C, and after melting, keep it for 10 - 15 min, then cast to obtain an alloy ingot; refine the alloy ingot at 1500 °C - 1680 °C. During the refining process, argon is introduced for protection, and the refining time is 90 - 120 min. Then, through gas atomization, the molten alloy liquid is broken and atomized into powders to obtain catalyst powders; screen the catalyst powders and select the fine catalyst powders with a particle size of 200 - 300 mesh; put the fine catalyst powders into a vacuum furnace, heat to 400 °C, then evacuate to a vacuum degree of 4 Pa, and then increase the temperature to 600 °C at a heating rate of 1.5 - 2 °C / min, then fill with hydrogen for reduction. Fill with hydrogen until the vacuum degree reaches 1 kPa, reduce for 30 min, then naturally cool to room temperature, and then through grinding and screening, obtain a catalyst powder for synthesizing self-sharpening diamond.

[0007] When the existing catalyst powder is prepared, it is not conducive to reducing the production cost of metal powders, not conducive to improving the powder utilization rate, and not conducive to regulating the width of the powder particle size distribution. Summary of the Invention

[0008] The purpose of the present invention is to provide a new gas atomization catalyst powder and its preparation process to reduce the production cost of metal powders, improve the powder utilization rate, and regulate the width of the powder particle size distribution.

[0009] To achieve the above object, the present invention provides the following technical solution: A novel gas atomized catalyst powder, comprising Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe, and by mass percentage, comprising the following components: 28-32% Ni, 2-4% Co, 1-3% Sn, 10-12% Mn, 2-4% Cr, 1-3% Cu, 2-4% Zn, and the balance being Fe.

[0010] As a preferred technical solution of the present invention, it comprises Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe, and by mass percentage, comprises the following components: 28% Ni, 2% Co, 1% Sn, 10% Mn, 2% Cr, 1% Cu, 2% Zn, and the balance being Fe.

[0011] As a preferred technical solution of the present invention, it comprises Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe, and by mass percentage, comprises the following components: 30% Ni, 3% Co, 2% Sn, 11% Mn, 3% Cr, 2% Cu, 3% Zn, and the balance being Fe.

[0012] As a preferred technical solution of the present invention, it comprises Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe, and by mass percentage, comprises the following components: 32% Ni, 4% Co, 3% Sn, 12% Mn, 4% Cr, 3% Cu, 4% Zn, and the balance being Fe.

[0013] The present invention also discloses a preparation process of the novel gas atomized catalyst powder, and the preparation process is as follows:

[0014] Step 1: Raw material preparation: The raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe;

[0015] Step 2: Melting: Place the raw materials in an intermediate frequency induction furnace for melting;

[0016] Step 3: Atomization: After melting and reaching the preset superheat degree, pour the obtained alloy liquid into the tundish to start atomization;

[0017] Step 4: Sedimentation: The atomized metal powder is solidified and sedimented in the atomization tower;

[0018] Step 5: Recovery: The sedimented metal powder falls into the powder collection tank for recycling.

[0019] As a preferred technical solution of the present invention, vacuum is pumped before melting, and an inert gas is filled for protection, and the atomization pressure is 3-5 MPa.

[0020] As a preferred technical solution of the present invention, the inert gas is one of nitrogen, helium, and argon.

[0021] As a preferred technical solution of the present invention, the preset superheat degree is 180 - 220K.

[0022] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0023] There is no need to use rare earth metals, reducing the production cost of metal powders;

[0024] The atomized metal powders are solidified and settled in the atomization tower; the settled metal powders fall into the powder collection tank for recycling, improving the powder recovery rate;

[0025] The prepared catalyst powder has a narrow particle size distribution and a high spherical slope, facilitating the regulation of the width of the powder particle size distribution. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a process flow chart for the preparation of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0028] Embodiment 1

[0029] Please refer to Figure 1 , which is the first embodiment of the present invention. This embodiment provides a novel gas atomized catalyst powder, including Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe. By mass percentage, it includes the following components: 28% Ni, 2% Co, 1% Sn, 10% Mn, 2% Cr, 1% Cu, 2% Zn, and the balance is Fe.

[0030] The preparation process of a novel gas atomized catalyst powder is as follows:

[0031] Step 1: Raw material preparation: The raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe; by mass percentage, it includes the following components: 28% Ni, 2% Co, 1% Sn, 10% Mn, 2% Cr, 1% Cu, 2% Zn, and the balance is Fe;

[0032] Step 2: Melting: Place the raw materials in an intermediate frequency induction furnace for melting; evacuate before melting and fill with an inert gas for protection, and the atomization pressure is 4MPa;

[0033] Step 3: Atomization: After melting and reaching the preset superheat of 200 K, the obtained alloy liquid is poured into the tundish to start atomization; the inert gas is nitrogen;

[0034] Step 4: Sedimentation: The atomized metal powder solidifies and sediments in the atomization tower;

[0035] Step 5: Recovery: The sedimented metal powder falls into the powder collection tank for recycling.

[0036] The atomization equipment, atomizing gas, and metal liquid flow are the three basic aspects of the gas atomization process; in the atomization equipment, the input atomizing gas is accelerated and interacts with the input metal liquid flow to form a flow field; in this flow field, the metal liquid flow breaks and cools and solidifies, thereby obtaining powder with certain characteristics; the parameters of the atomization equipment include the nozzle structure, the structure of the liquid guiding tube, the position of the liquid guiding tube, and the atomizing gas and its process parameters include the gas properties, the inlet gas pressure, and the gas flow velocity, while the metal liquid flow and its process parameters include the properties of the metal liquid flow, the superheat, and the liquid flow diameter; gas atomization adjusts the powder particle size, particle size distribution, and microstructure by adjusting each parameter and the coordination of each parameter.

[0037] The mainstream atomization processes are all carried out in a vacuum or inert gas environment to reduce the oxygen content and impurity content in the powder and improve the purity of the powder; research shows that the oxygen in the powder is basically introduced during the smelting process; therefore, a vacuum or inert gas environment should be maintained both in the preparation of the master alloy and during the atomization process; after the master alloy melts, it is broken and dispersed into small droplets by a high-pressure and high-speed gas flow (inert gas), and the small droplets quickly lose heat during the falling process and quickly solidify into spherical powder under the action of surface tension.

[0038] Currently, various studies on gas atomization mainly focus on two aspects; on the one hand, studying the nozzle structure parameters and the characteristics of the injection gas flow; the purpose is to obtain the relationship between the gas flow field and the nozzle structure so that the gas reaches the maximum speed and the gas flow rate is the minimum at the nozzle outlet, providing a theoretical basis for the design and processing of the nozzle; on the other hand, studying the relationship between the atomization process parameters and the powder properties; it aims to study the influence of the atomization process parameters on the powder characteristics and atomization efficiency based on a specific nozzle to optimize and guide the production of the powder; improving the productivity of fine powder and reducing the gas consumption guide the development direction of gas atomization technology.

[0039] The atomizing gas passes through the nozzle to increase its speed and energy, thereby effectively breaking the liquid metal and producing powders that meet the requirements. The nozzle controls the flow and flow pattern of the atomizing medium, playing a crucial role in the atomization efficiency and the stability of the atomization process. It is the key technology of gas atomization. In the early gas atomization processes, the free-fall nozzle structure was commonly used. This nozzle has a simple design, is not easily blocked, and the control process is relatively simple. However, its atomization efficiency is not high, and it is only suitable for producing powders with a particle size of 50 - 300 μm. To improve the atomization efficiency, the restricted nozzle or the close-coupled atomizing nozzle was developed later. The close-coupled or restricted nozzle shortens the gas flight distance, reduces the kinetic energy loss during the gas flow process, thereby increasing the speed and density of the gas flow acting on the metal and increasing the yield of fine powders.

[0040] The sample powder was analyzed by standard sieving. For the powder with a particle size ≤ 25 μm after sieving, the particle size analysis was carried out using a laser particle size analyzer. The particle size distribution curve of the powder was obtained by weighting the sieve analysis results and the particle size analyzer results. The surface morphology of the powder was observed using a scanning electron microscope. The morphology of the gas atomized catalyst powder obtained from the experiment is as follows: Most of the obtained powders are regular spherical or near-spherical, and a small number of powders are irregular shapes such as rod-shaped. In addition, most of the powder particle sizes are below 50 μm, which is consistent with the particle size distribution obtained from the sieve analysis. Powders with different particle sizes have different sphericity and surface roughness. Generally speaking, powders with larger particle sizes have relatively lower sphericity and rougher surfaces, while powders with smaller particle sizes have relatively higher sphericity and smoother surfaces.

[0041] Example 2

[0042] Please refer to Figure 1 , which is the second embodiment of the present invention. This embodiment provides a new type of gas atomized catalyst powder, including Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe. By mass percentage, it includes the following components: 30% Ni, 3% Co, 2% Sn, 11% Mn, 3% Cr, 2% Cu, 3% Zn, and the balance is Fe.

[0043] The preparation process of a new type of gas atomized catalyst powder is as follows:

[0044] Step 1: Raw material preparation: The raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe. By mass percentage, it includes the following components: 30% Ni, 3% Co, 2% Sn, 11% Mn, 3% Cr, 2% Cu, 3% Zn, and the balance is Fe.

[0045] Step 2: Melting: The raw materials are placed in an intermediate frequency induction furnace for melting. Before melting, the vacuum is pumped and an inert gas is filled for protection. The atomization pressure is 3 MPa.

[0046] Step 3: Atomization: After melting and reaching the preset superheat of 180K, the obtained alloy liquid is poured into the tundish to start atomization; the inert gas is helium;

[0047] Step 4: Sedimentation: The atomized metal powder undergoes solidification and sedimentation in the atomization tower;

[0048] Step 5: Recycling: The sedimented metal powder falls into the powder collection tank for recycling.

[0049] The atomization equipment, atomizing gas and metal liquid flow are three basic aspects of the gas atomization process; in the atomization equipment, the input atomizing gas is accelerated and interacts with the input metal liquid flow to form a flow field; in this flow field, the metal liquid flow breaks and cools and solidifies, thereby obtaining powder with certain characteristics; the parameters of the atomization equipment include the nozzle structure, the structure of the liquid delivery pipe, the position of the liquid delivery pipe, and the atomizing gas and its process parameters include the gas properties, the inlet pressure, and the gas flow velocity, while the metal liquid flow and its process parameters include the properties of the metal liquid flow, the superheat, and the liquid flow diameter; gas atomization adjusts the powder particle size, particle size distribution and microstructure by adjusting each parameter and the coordination of each parameter.

[0050] The mainstream atomization processes are carried out in a vacuum or inert gas environment to reduce the oxygen content and impurity content in the powder and improve the purity of the powder; research shows that the oxygen in the powder is basically introduced during the melting process; therefore, a vacuum or inert gas environment should be maintained both in the preparation of the master alloy and during the atomization process; after the master alloy melts, it is broken and dispersed into small droplets by a high-pressure and high-speed gas flow (inert gas), and the heat of the small droplets is quickly dissipated during the falling process and quickly solidifies into spherical powder under the action of surface tension.

[0051] Currently, various studies on gas atomization mainly focus on two aspects; on the one hand, studying the structural parameters of the nozzle and the characteristics of the jet airflow; the purpose is to obtain the relationship between the airflow field and the nozzle structure, so that the airflow reaches the maximum speed and the gas flow rate is minimized at the nozzle outlet, providing a theoretical basis for the design and processing of the nozzle; on the other hand, studying the relationship between the atomization process parameters and the powder properties; it aims to study the influence of the atomization process parameters on the powder characteristics and atomization efficiency based on a specific nozzle to optimize and guide the production of the powder; improving the productivity of fine powder and reducing the gas consumption guide the development direction of the gas atomization technology.

[0052] The atomizing gas passes through the nozzle to increase its speed and energy, thereby effectively breaking the liquid metal and preparing powders that meet the requirements. The nozzle controls the flow and flow pattern of the atomizing medium, which plays a crucial role in the atomization efficiency and the stability of the atomization process. It is the key technology of gas atomization. In the early gas atomization processes, free-falling nozzle structures were commonly used. This type of nozzle has a simple design, is not easily blocked, and the control process is relatively simple. However, its atomization efficiency is not high, and it is only suitable for producing powders with particle sizes of 50 - 300 μm. To improve the atomization efficiency, restricted nozzles or close-coupled atomizing nozzles were developed later. The close-coupled or restricted nozzles shorten the gas flight distance, reduce the kinetic energy loss during the gas flow process, thereby increasing the speed and density of the gas stream acting on the metal and increasing the yield of fine powders.

[0053] The sample powders were analyzed by standard sieving. Powders with particle sizes ≤ 25 μm after sieving were analyzed for particle size using a laser particle size analyzer. The particle size distribution curve of the powders was obtained by weighting the sieve analysis results and the particle size analyzer results. The surface morphology of the powders was observed using a scanning electron microscope. The morphology of the gas atomized catalyst powders obtained from the experiment is as follows: Most of the obtained powders are in regular spherical or near-spherical shapes, and a small number of powders are in irregular shapes such as rod shapes. In addition, most of the powder particle sizes are below 50 μm, which is consistent with the particle size distribution obtained from sieve analysis. Powders with different particle sizes have different sphericities and surface roughnesses. Generally speaking, powders with larger particle sizes have relatively lower sphericities and rougher surfaces, while powders with smaller particle sizes have relatively higher sphericities and smoother surfaces.

[0054] Example 3

[0055] Please refer to Figure 1 , which is the third embodiment of the present invention. This embodiment provides a new type of gas atomized catalyst powder, including Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe. By mass percentage, it includes the following components: 32% Ni, 4% Co, 3% Sn, 12% Mn, 4% Cr, 3% Cu, 4% Zn, and the balance is Fe.

[0056] The preparation process of a new type of gas atomized catalyst powder is as follows:

[0057] Step 1: Raw material preparation: The raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, Fe. By mass percentage, it includes the following components: 32% Ni, 4% Co, 3% Sn, 12% Mn, 4% Cr, 3% Cu, 4% Zn, and the balance is Fe.

[0058] Step 2: Melting: Place the raw materials in an intermediate frequency induction furnace for melting. Vacuum is pumped before melting, and an inert gas is filled for protection. The atomization pressure is 5 MPa.

[0059] Step 3: Atomization: After melting and reaching the preset superheat of 220 K, the obtained alloy liquid is poured into the tundish to start atomization; the inert gas is argon;

[0060] Step 4: Sedimentation: The atomized metal powder undergoes solidification and sedimentation in the atomization tower;

[0061] Step 5: Recycling: The sedimented metal powder falls into the powder collection tank for recycling.

[0062] The atomization equipment, atomizing gas and metal liquid flow are three basic aspects of the gas atomization process; in the atomization equipment, the input atomizing gas is accelerated and interacts with the input metal liquid flow to form a flow field; in this flow field, the metal liquid flow breaks and cools to solidify, thereby obtaining powder with certain characteristics; the parameters of the atomization equipment include the nozzle structure, the structure of the liquid delivery pipe, the position of the liquid delivery pipe, and the atomizing gas and its process parameters include the gas properties, the inlet pressure, and the gas flow velocity, while the metal liquid flow and its process parameters include the properties of the metal liquid flow, the superheat, and the liquid flow diameter; gas atomization adjusts the powder particle size, particle size distribution and microstructure by adjusting each parameter and the coordination of each parameter.

[0063] The mainstream atomization processes are carried out in a vacuum or inert gas environment to reduce the oxygen content and impurity content in the powder and improve the purity of the powder; research shows that the oxygen in the powder is basically introduced during the melting process; therefore, a vacuum or inert gas environment should be maintained both in the preparation of the master alloy and during the atomization process; after the master alloy melts, it is broken and dispersed into small droplets by a high-pressure and high-speed gas flow (inert gas), and the heat of the small droplets quickly dissipates during the falling process and quickly solidifies into spherical powder under the action of surface tension.

[0064] Currently, various studies on gas atomization mainly focus on two aspects; on the one hand, studying the structural parameters of the nozzle and the characteristics of the jet gas flow; the purpose is to obtain the relationship between the gas flow field and the nozzle structure, so that the gas reaches the maximum speed and the gas flow rate is minimized at the nozzle outlet, providing a theoretical basis for the design and processing of the nozzle; on the other hand, studying the relationship between the atomization process parameters and the powder properties; it aims to study the influence of the atomization process parameters on the powder characteristics and atomization efficiency based on a specific nozzle to optimize and guide the powder production; improving the productivity of fine powder and reducing the gas consumption guides the development direction of gas atomization technology.

[0065] The atomizing gas passes through the nozzle to increase its speed and energy, thus effectively breaking the liquid metal and producing powders that meet the requirements. The nozzle controls the flow and flow pattern of the atomizing medium, playing a crucial role in the atomization efficiency and the stability of the atomization process. It is the key technology of gas atomization. In the early gas atomization processes, the free-fall nozzle structure was commonly used. This kind of nozzle has a simple design, is not easily blocked, and the control process is relatively simple. However, its atomization efficiency is not high and it is only suitable for producing powders with a particle size of 50 - 300 um. To improve the atomization efficiency, the restricted nozzle or the close-coupled atomizing nozzle was developed later. The close-coupled or restricted nozzle shortens the gas flight distance, reduces the kinetic energy loss during the gas flow process, thus increasing the speed and density of the gas flow acting on the metal, and increasing the production of fine powders.

[0066] The standard sieve analysis was carried out on the sample powders. For the powders with a particle size ≤ 25 um after sieving, the particle size analysis was carried out using a laser particle size analyzer. The particle size distribution curve of the powders was obtained by weighting the sieve analysis results and the results of the particle size analyzer. The surface morphology of the powders was observed using a scanning electron microscope. The morphology of the gas atomized catalyst powders obtained from the experiment is as follows: Most of the obtained powders are regular spherical or near-spherical, and a small number of powders are irregular shapes such as rod-shaped. In addition, most of the powder particle sizes are below 50 um, which is consistent with the particle size distribution obtained from the sieve analysis. Powders with different particle sizes have different sphericity and surface roughness. Generally speaking, powders with larger particle sizes have relatively lower sphericity and rougher surfaces, while powders with smaller particle sizes have relatively higher sphericity and smoother surfaces.

[0067] The properties of the molten metal and the atomization pressure affect the fineness and particle size distribution of the powders. Molten metals with low viscosity, low surface tension, and high density can produce finer powders. When the flow rate of the molten metal increases, the particle size of the powders also increases accordingly. When the ratio of the gas flow rate to the melt flow rate remains unchanged, further increasing the atomization pressure hardly affects the particle size distribution. Increasing the atomization medium pressure will result in a smaller particle size. The negative pressure at the end of the guide tube is related to the atomization pressure. The lower the negative pressure, the smaller the particle size of the powders, and the greater the energy exchange degree between the gas and the melt.

[0068] The molten metal must have a certain degree of superheat before it can be atomized stably. The higher the temperature of the molten metal, the lower its viscosity. Therefore, increasing the superheat of the melt can produce finer metal powders. However, when the superheat increases to a certain extent, it will affect the powder properties because too high melt temperature will lead to an increase in the solidification time, and the droplets are prone to stick and fuse with each other during the flight process, and it will also increase the probability of satellite powder appearance, which is not conducive to powder forming.

[0069] Different atomizing gases also affect the fineness and particle size distribution of powders; some scholars have studied the influence of different atomizing media on the particle size of aluminum powder; it was found that the powder obtained by helium atomization is the finest, nitrogen is in the middle, and the powder obtained by argon atomization has the largest particle size; this is because the surface heat transfer coefficient of helium is the highest, and the degree of energy exchange with the metal liquid flow is the largest.

[0070] Although the embodiments of the present invention have been shown and described, see the above detailed description, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A novel aerosolized catalyst powder, characterized by: Calculated by mass percentage, it includes the following components: 28-32% Ni, 2-4% Co, 1-3% Sn, 10-12% Mn, 2-4% Cr, 1-3% Cu, 2-4% Zn, and the balance is Fe.

2. The novel aerosolized catalyst powder according to claim 1, characterized in that: Calculated by mass percentage, it includes the following components: 28% Ni, 2% Co, 1% Sn, 10% Mn, 2% Cr, 1% Cu, 2% Zn, and the balance is Fe.

3. The novel aerosolized catalyst powder according to claim 1, characterized in that: Calculated by mass percentage, it includes the following components: 30% Ni, 3% Co, 2% Sn, 11% Mn, 3% Cr, 2% Cu, 3% Zn, and the balance is Fe.

4. The novel aerosolized catalyst powder according to claim 1, characterized in that: Calculated by mass percentage, it includes the following components: 32% Ni, 4% Co, 3% Sn, 12% Mn, 4% Cr, 3% Cu, 4% Zn, and the balance is Fe.

5. A process for preparing a novel aerosolized catalyst powder according to any one of claims 1 to 4, characterized in that: The preparation process is as follows: Step 1: Raw material preparation: Raw materials include Ni, Co, Sn, Mn, Cr, Cu, Zn, and Fe; Step 2: Melting: Place the raw materials in a medium frequency induction furnace for melting; Step 3: Atomization: After melting and reaching the preset superheat, the obtained alloy liquid is poured into the tundish and atomization begins; Step 4: Sedimentation: The atomized metal powder solidifies and settles in the atomization tower; Step 5: Recycling: The settled metal powder falls into the powder collecting tank for recycling.

6. The process for preparing a novel aerosolized catalyst powder according to claim 5, characterized in that: Before melting, the chamber is vacuumed and filled with inert gas for protection, with an atomization pressure of 3-5 MPa.

7. The process for preparing a novel aerosolized catalyst powder according to claim 6, characterized in that: The inert gas is one of nitrogen, helium and argon.

8. The process for preparing a novel aerosolized catalyst powder according to claim 5, characterized in that: The preset superheat is 180-220K.

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