Cold Tundish Atomization for Reactive Metal Powders
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Solution Overview
Problem
Current methods for producing spheroidal powders of reactive or refractory metals, such as titanium, face challenges in achieving high yields of ultrafine particles from a variety of feedstock configurations, while being economically and efficiently viable.
Innovation Solution
The apparatus employs a cold tundish with a high thermal conductivity entrance-side portion and a cooling duct, combined with a second heating device and a jet opening for high-velocity fluid flow, which atomizes the molten material, allowing for efficient production of spheroidal powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional gas atomization methods are used, then spheroidal powders can be produced, but high yields of ultrasmall particles cannot be achieved from diverse feedstock configurations
Solution Approach 1:
The patent changes the temperature parameter of the tundish from conventional hot to controlled cold temperatures, which fundamentally alters the material state and enables precise control over particle size and yield while accommodating diverse feedstock configurations
Solution Approach 2:
The system dynamically adjusts processing parameters including temperature, gas flow rates, and feedstock introduction rates to optimize powder production from varying feedstock types, enabling high yield and precise particle size control across different materials
2Reliability
If cold crucible is used to process reactive metals, then crucible damage is prevented, but contamination of molten material occurs
Solution Approach 1:
The patent introduces a protective barrier layer or intermediary substance between the cold crucible walls and the molten reactive metal, preventing direct contact that would cause contamination while maintaining the crucible's cold temperature structure
Solution Approach 2:
The system employs an inert atmosphere or protective gas environment within the cold crucible to prevent reactive metals from contaminating the crucible structure and vice versa, maintaining material purity while using cold crucible design
3Loss of energy
If close-coupled gas atomization is used, then gas consumption is reduced, but molten material freezing in the nozzle occurs
Solution Approach 1:
The patent dynamically controls the temperature of the nozzle and tundish to remain below the melting point of the material, preventing freezing while using controlled gas flows that avoid clogging, allowing close-coupled configuration with reduced gas consumption
Solution Approach 2:
The system changes the temperature parameter of the nozzle from hot to cold, fundamentally preventing material freezing and clogging while maintaining efficient gas atomization with reduced gas consumption through controlled cooling
4Device complexity
If freefall gas atomization is used, then crucible design is simplified, but particle size uniformity deteriorates
Solution Approach 1:
The patent changes the temperature parameter of the tundish to controlled cold temperatures, which fundamentally improves particle size uniformity by controlling material state and solidification, while maintaining the simplified freefall crucible design
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
This approach enables the production of high-yield, ultrafine spheroidal powders from diverse feedstock configurations, overcoming previous limitations in control over particle size, uniformity, efficiency, scalability, and compatibility with various feedstocks.
Implementation Method 1
an entrance-side portion that is made from a high thermal conductivity material and a cooling duct configured to carry a coolant fluid for cooling the thermally conductive entrance-side portion
Implementation Method 2
a second heating device provided, configured so as to heat molten material that is in or on the cold tundish
Implementation Method 3
a jet opening for producing a high velocity fluid flow that impinges on, and atomizes, the discharged molten material
Implementation Method 4
Surface tension of the molten material causes the droplets to assume substantially spherical geometries
Data Source
AI summary
A cold tundish which has a surface made from a thermally conductive metal, and which is cooled by a cooling fluid, is disposed so as to receive a molten material from a cold crucible; high-speed jets of an inert gas are produced from a nozzle at a narrow portion of an orifice that is open at the exit side of the cold tundish, producing a low-pressure region on the exit side of the orifice that draws the molten material and a plasma through the orifice; the high-speed jets of inert gas impinge on the molten material to achieve atomization thereof, using an apparatus that is compatible with atomization of even reactive and refractory metals.