Electric Arc Wire Powdering for Low-Oxygen Spherical Particles
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Solution Overview
Problem
Existing powder preparation processes, such as electrode induction melting gas atomization (EIGA) and electric arc processes, fail to achieve a well-controlled oxygen content and composition, leading to energy inefficiency and unsatisfactory particle size distribution, with a tendency for oxidation and sintering.
Innovation Solution
A process involving the controlled dispensing and melting of two wires using an electric arc, followed by spraying, cooling, and enriching with active substances to form spherical particles, with a push-pull feeder system to minimize oxygen content, and a short-circuit transfer regime to control particle size and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electric arc melting with conventional feeding is used, then melting and spraying can be achieved, but oxygen content in the powder is not well-controlled and oxidation occurs
Solution Approach 1:
The patent applies dynamic push-pull feeding mechanism where the wire is alternately pushed and pulled during the dispensing process. This dynamic motion minimizes the wire's exposure time to oxygen-containing environments and prevents oxidation by continuously moving the wire through controlled zones, thereby achieving well-controlled oxygen content in the resulting powder particles.
Solution Approach 2:
The patent implements an inert atmosphere system that surrounds the wire dispensing and melting zone. By maintaining an inert environment (typically using argon or nitrogen gas), the oxidation of molten metal and wire surface is prevented during the entire process, enabling precise control of oxygen content in the produced powder.
2Manufacturing precision
If conventional feeding systems are used, then simple equipment operation is achieved, but particle size distribution is unsatisfactory
Solution Approach 1:
The push-pull feeding system dynamically adjusts wire movement during dispensing, creating optimal conditions for consistent droplet formation and particle size control. The alternating push and pull actions ensure uniform material flow to the electric arc, resulting in satisfactory particle size distribution in the produced powder.
Solution Approach 2:
The feeding system incorporates feedback mechanisms that monitor and adjust the wire dispensing rate based on process conditions. This closed-loop control ensures stable material feed to the melting zone, maintaining consistent particle size distribution while managing the complexity of the feeding system through intelligent control.
3Shape
If high energy processes like EIGA are used, then spherical powder can be obtained, but energy consumption is very high
Solution Approach 1:
The patent utilizes controlled phase transitions of the metal material from solid wire to molten droplets and finally to solidified powder particles. The electric arc provides localized melting, and the rapid cooling during spraying achieves spherical particle formation through controlled solidification, reducing overall energy consumption compared to continuous high-energy processes like EIGA.
Solution Approach 2:
The invention extracts only the essential energy input needed for melting and spraying, removing unnecessary energy-consuming steps from conventional processes. By using electric arc for localized heating and immediate spraying of molten material, the process achieves spherical powder with significantly reduced energy consumption compared to full induction melting systems.
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 achieves lower oxygen content, controlled particle size distribution, reduced oxidation, and improved composition reproducibility, meeting ASTM standards for powders like Ti6Al4V, suitable for additive manufacturing.
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
by means of 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 in such a way as to form solid particles
Data Source
AI summary
A preparation process for preparing powder from a first material and a second material, having: a step of dispensing wires made of the materials by means of a feeder and an additional feeder, a melting step of melting the wires, a spraying step of spraying in such a way as to form droplets, a cooling step of cooling the droplets in such a way as to form solid particles, a separation and collection step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder, and, during the dispensing step, the wires are firstly pushed by the feeder, then pulled by the additional feeder, and then pushed by the additional feeder towards said electric arc.