Dual Wire Arc Plasma Atomization for High Purity Metal Powders
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Solution Overview
Problem
Current plasma atomization technologies have low production rates and inefficiencies due to high energy consumption and contamination issues, while wire arc spray produces irregular powders unsuitable for many applications.
Innovation Solution
A dual wire arc plasma atomization process using a thermal plasma torch with an electrical arc to atomize and cool molten wires, optimizing production rates and powder quality by controlling arc stability and using an anti-satellite diffuser to prevent satellite formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If plasma atomization is used to produce fine spherical powders, then powder quality (sphericity, density, fine particle size) is improved, but production rate remains low
Solution Approach 1:
The invention merges plasma atomization and wire arc spray technologies into a hybrid process. The plasma torch provides the high-temperature environment for melting and atomizing the wire, while the wire arc provides additional heat and molten metal droplets. This combination allows the process to achieve the fine spherical powder quality of plasma atomization while attaining the high production rates of wire arc spray.
2Productivity
If three plasma torches are used to increase production rate, then productivity is improved, but heat transfer efficiency decreases and contamination increases
Solution Approach 1:
The invention combines the functions of multiple plasma torches and wire arc systems into a unified hybrid apparatus. Instead of using three separate plasma torches that each suffer from low heat transfer efficiency, the hybrid system integrates one or more plasma torches with wire arc technology, where the wire arc provides direct contact heating with much higher efficiency while the plasma torch contributes to atomization and powder formation.
3Productivity
If wire arc spray is used to increase production rate, then productivity is improved, but powder sphericity and quality deteriorate
Solution Approach 1:
The hybrid process merges wire arc spray's high productivity with plasma atomization's superior powder quality. The wire arc component maintains high production rates through efficient melting and droplet generation, while the plasma torch component ensures fine spherical morphology through controlled atomization and rapid cooling in an inert atmosphere, eliminating the angular irregularities characteristic of conventional wire arc spray.
4Productivity
If plasma atomization operates at upper bound production rates, then productivity is improved, but particle size becomes coarser
Solution Approach 1:
The hybrid system combines the high-rate melting capability of wire arc spray with the fine atomization capability of plasma torches. The wire arc provides abundant molten metal at high rates, while the plasma torch efficiently breaks up the molten stream into fine droplets through plasma jet impingement and gas dynamic atomization, maintaining fine particle size distributions even at elevated production rates.
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 method achieves higher production rates with improved powder quality, producing spherical and dense powders efficiently, addressing the inefficiencies of existing plasma atomization and irregularity of wire arc spray technologies.
Implementation Method 1
an electrical arc transferred to the wire or wires to be atomized
Implementation Method 2
an electrical arc transferred to the wire or wires to be atomized
Implementation Method 3
a thermal plasma torch
Implementation Method 4
a thermal plasma torch
Implementation Method 5
a cooling process adapted to solidify the particles into spherical powders
Data Source
AI summary
The present application relates to a plasma atomization process and apparatus for producing metallic powders from at least one wire/rod feedstock. In the process, an electrical arc is applied between the at least one wire/rod feedstock, and a plasma torch is employed to generate a supersonic plasma stream at an apex at which the electric arc is transferred to the at least one wire/rod to melt and atomize the at least one wire/rod feedstock to produce the metallic powders. An anti-satellite diffuser is employed to prevent recirculation of the powders in order to avoid satellite formation.