Arc Powder Production with Pulsed Current for Particle Size Control
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Solution Overview
Problem
Existing powder manufacturing processes, such as the EIGA process and those described in EP4221916A1, face challenges in controlling particle size distribution and material composition, leading to high energy consumption and additional separation costs.
Innovation Solution
A process utilizing a short-circuit electric current with specific voltage and frequency ranges, combined with controlled gas pressures and material distribution, to form droplets that are cooled and enriched with active substances, followed by precise separation and collection steps to achieve controlled particle size and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electric arc processes (EIGA, EP 4221916 A1) are used to manufacture powder, then spherical metallic powders can be obtained with limited contamination, but energy consumption is very high and particle size distribution cannot be easily controlled
Solution Approach 1:
The invention changes the electrical parameters from conventional high-voltage DC arc to pulsed current with specific characteristics (frequency 40-200 Hz, voltage 10-30 V, current intensity 50-400 A). This parameter change enables better control of droplet formation and solidification, achieving controlled particle size distribution while reducing energy consumption through more efficient melting and spraying cycles.
2Manufacturing precision
If conventional electric arc processes are used to manufacture powder, then spherical metallic powders can be obtained with limited contamination, but the process is not easy to implement
Solution Approach 1:
The invention introduces dynamic control through pulsed current with adjustable frequency (40-200 Hz) and amplitude, allowing real-time optimization of droplet formation, flight time, and solidification. This dynamic approach simplifies implementation by enabling adaptive control of particle size distribution without requiring complex mechanical adjustments or multiple processing stages.
3Manufacturing precision
If the disclosed process from EP 4221916 A1 is used, then powder can be manufactured from first and second materials, but additional separation steps are required to obtain controlled particle size distribution, making the process costly
Solution Approach 1:
The invention performs preliminary action by controlling the droplet formation and solidification parameters during the manufacturing process itself. By optimizing pulsed current parameters (frequency 40-200 Hz, voltage 10-30 V, current intensity 50-400 A) and carrier gas pressure (4-12 bar), the process produces particles with desired size distribution directly, eliminating the need for subsequent separation steps and reducing overall process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process produces powders with improved particle size distribution and reduced contamination, meeting industry standards like ASTM F3001-14 and ASTM F2924-14, while minimizing energy use and production costs.
Implementation Method 1
a step of melting the first and second materials, by means of an electric arc formed by the application of an electric current between said first and second materials
Implementation Method 2
an electric arc formed by the application of an electric current between said first and second materials
Implementation Method 3
a step of cooling the droplets by means of a carrier gas so as to form solid particles
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method for manufacturing (100) powder from a first material and a second material (1a, 1b) comprising: a step of melting the first and second materials by means of an electric arc (314), a step of spraying the first and second molten materials so as to form droplets (2), a step of cooling the droplets by means of a carrier gas (11) so as to form solid particles, a step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder (5), the electric current applied to form the electric arc being a short-circuit current.