Atomized Powder Ultrafine Particle Removal via Liquid Agitation
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Solution Overview
Problem
Reactive metal powders produced through atomization often contain ultrafine particles that adhere to fine particles, reducing flowability due to increased roughness and electromagnetic interactions, which existing sieving processes cannot effectively remove.
Innovation Solution
An ultrafine particle removal process involving the use of a removal liquid and energy addition, such as ultrasonic energy or mechanical agitation, to detach ultrafine particles from fine particles, followed by separation and recirculation of the removal liquid, enhancing the flowability of the resulting powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sieving processes are used to separate particles, then particle size classification is achieved, but ultrafine particles adhering to fine particles cannot be effectively removed
Solution Approach 1:
A liquid medium is introduced as an intermediary between the ultrafine and fine particles. The liquid penetrates the interface between adhered particles, utilizing surface tension and wetting effects to separate the ultrafine particles from the fine particles, enabling effective removal that conventional dry sieving cannot achieve
Solution Approach 2:
Hydraulic action is employed by circulating liquid through the powder bed. The liquid flow generates shear forces and pressure differentials that detach ultrafine particles from fine particles, followed by filtration and recirculation of the liquid to continuously remove separated ultrafine particles
2Productivity
If ultrafine particles are present on fine particles, then powder production is maintained, but flowability is reduced due to increased roughness and electromagnetic interactions
Solution Approach 1:
The harmful ultrafine particles are extracted and removed from the surface of fine particles using liquid penetration and hydraulic separation. This extraction process eliminates the sources of increased roughness and electromagnetic interactions, thereby restoring and improving powder flowability while maintaining production of usable fine powder
Solution Approach 2:
The physical state and surface properties of particles are changed by introducing liquid medium. The liquid temporarily alters surface energy and inter-particle forces during processing, enabling separation. After liquid removal, particles exhibit improved flow characteristics due to reduced adhesion and roughness
3Ease of operation
If removal liquid is used to detach ultrafine particles, then flowability is improved, but additional processing steps and equipment complexity are introduced
Solution Approach 1:
The removal liquid is filtered to separate and discard ultrafine particles, then the cleaned liquid is recirculated back into the system for continued use. This recovery and recirculation approach minimizes liquid consumption and reduces waste handling requirements, offsetting the added equipment complexity with operational efficiency
Solution Approach 2:
The liquid medium serves multiple functions simultaneously: it acts as a separation agent to detach particles, as a transport medium to carry separated particles away, and as a recirculable resource that can be reused. This multi-functionality consolidates several process steps into one integrated system, reducing overall 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
Significantly improves the flowability of reactive metal powders by removing ultrafine particles, achieving a substantial increase in volumetric flowability and maintaining a high mass retention of the finished powder, suitable for applications like additive manufacturing.
Implementation Method 1
adding energy to a mixture of the atomized powder and the removal liquid to detach the ultrafine particles from the fine particles
Implementation Method 2
adding energy to a mixture of the atomized powder and the removal liquid to detach the ultrafine particles from the fine particles
Implementation Method 3
contacting the atomized powder with a removal liquid to form a mixture of the atomized powder and the removal liquid
Implementation Method 4
separating the removal liquid and the ultrafine particles from the fine particles
Implementation Method 5
adding energy to a mixture of the atomized powder and the removal liquid to detach the ultrafine particles from the fine particles
Data Source
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AI summary
A method for removing ultrafine particles (206) from an atomized powder (306) is provided. The method includes contacting the atomized powder (306) with a removal liquid (324), the atomized powder (306) comprising fine particles (202) and ultrafine particles (206), wherein contacting the atomized powder (306) with the removal liquid (324) comprises adding energy to a mixture (336) of the atomized powder (306) and the removal liquid (324) to detach the ultrafine particles (206) from the fine particles (202); and separating the removal liquid (324) and ultrafine particles (206) from the fine particles (202).