Fluidized Bed Heat Treatment for Atomized Powder Homogeneity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Atomized metal alloy powders used in additive manufacturing exhibit nonhomogeneous microstructures due to chemical segregation, which can lead to poor particle-particle bonding and weakening of the material during solid-state consolidation processes like cold spray, as seen in alloys such as aluminum alloy 7075.
Innovation Solution
A system utilizing a fluidized bed for heat treatment and degassing of atomized powders, with inert gas processing and quenching, to control microstructure and achieve chemical homogeneity, similar to conventional alloy ingot treatments, thereby enhancing solid-state consolidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If atomized powder is used as feedstock for additive manufacturing, then manufacturing complexity is reduced and production speed is improved, but microstructural homogeneity deteriorates due to chemical segregation
Solution Approach 1:
The patent applies preliminary heat treatment to the atomized powder before additive manufacturing. The powder is heated to a first temperature for a first time period to promote diffusion and chemical homogenization, then cooled. This preliminary action corrects the microstructural defects (chemical segregation) that occur during atomization, enabling the powder to achieve desired microstructural homogeneity while maintaining the productivity benefits of using atomized powder as feedstock.
2Ease of manufacture
If atomized powder is used for additive manufacturing, then manufacturing cost is reduced and production time is saved, but bonding strength deteriorates due to poor particle-particle bonding
Solution Approach 1:
The patent applies preliminary heat treatment to the atomized powder before additive manufacturing. The powder is heated to a first temperature for a first time period to promote diffusion and chemical homogenization, then cooled. This preliminary action corrects the microstructural defects (chemical segregation) that occur during atomization, enabling the powder to achieve desired microstructural homogeneity while maintaining the productivity benefits of using atomized powder as feedstock.
3Stability of the object's composition
If heat treatment is applied to atomized powder to control microstructure, then microstructural homogeneity is improved, but processing time and energy consumption increase
Solution Approach 1:
The patent specifies particular heat treatment parameters: heating to a first temperature (e.g., 400-600°C for aluminum alloys) for a first time period (e.g., 1-10 minutes), then cooling. These parameter changes are optimized to achieve the desired microstructural homogeneity and bonding strength while minimizing processing time and energy consumption. The temperature and time parameters are selected to promote sufficient diffusion for chemical homogenization without excessive processing time.
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 system effectively eliminates segregation, improving the bonding between powder particles and achieving a microstructural condition ideal for robust solid-state consolidation, enhancing the mechanical properties of the final parts.
Implementation Method 1
heating the atomized powder in the fluidized bed, the feedstock alloy powders heat treated for microstructure control
Implementation Method 2
A fluidized bed operable to heat treat feedstock alloy powders, the feedstock alloy powders heat treated for microstructure control
Implementation Method 3
the feedstock alloy powders are degassed
Implementation Method 4
communicating an inert gas into a fluidized bed
Implementation Method 5
communicating the atomized powder into a quenching reservoir
Implementation Method 6
quenching the atomized powder
Implementation Method 7
communicating the atomized powder to the fine powder collector through a water bubbler
Data Source
AI summary
A system for treatment of atomized powder including a fluidized bed operable to treat feedstock alloy powders. A method of treating atomized powder including communicating an inert gas into a fluidized bed; communicating an atomized powder into the fluidized bed; and heating the atomized powder in the fluidized bed, eject the treated powders out of the fluidized bed to quench the powders.