Continuous Gas Atomization of Molten Steel for Additive Manufacturing
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Solution Overview
Problem
Current steel powder production methods by gas atomization are not compatible with large-scale, continuous production and cannot easily accommodate varying raw materials or steel compositions, limiting their versatility for additive manufacturing.
Innovation Solution
A process involving molten iron refinement in a converter, followed by adjustment with ferroalloys in induction furnaces, and subsequent gas atomization to produce steel powders with desired compositions in a continuous mode, using a blast furnace, converter, ladle metallurgy furnace, and gas atomizers, allowing for flexible composition and continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing is used in conventional steel powder production, then quality control is maintained, but productivity is limited and continuous production is not achievable
Solution Approach 1:
The system divides the steel powder production into multiple independent induction furnaces (at least two) that can operate simultaneously and continuously. Each furnace is equipped with its own gas atomizer and reservoir, allowing parallel processing of multiple steel compositions or batches without compromising quality control, thereby achieving continuous high-volume production.
Solution Approach 2:
The process enables continuous operation by maintaining molten steel in induction furnaces and continuously feeding it to gas atomizers through reservoirs. The system can operate 24/7 without interruption, converting molten iron from the blast furnace into steel powder continuously, thus eliminating the batch processing limitations of conventional methods.
2Adaptability or versatility
If conventional gas atomization is used, then steel powder production is achieved, but adaptability to different raw materials and compositions is limited
Solution Approach 1:
The induction furnaces are designed to handle various types of raw materials (molten iron from blast furnace, scrap steel, direct reduced iron) and can produce different steel compositions by adjusting ferroalloy additions. The system can accommodate multiple steel grades and compositions simultaneously in different furnaces, making it universally adaptable to diverse raw materials and product requirements without requiring separate dedicated lines for each material type.
Solution Approach 2:
The system dynamically adjusts the steel composition by controlling ferroalloy additions in each induction furnace based on real-time requirements. The process can adapt composition parameters (carbon, silicon, manganese, chromium, nickel content) by adjusting addition rates and types of ferroalloys, enabling flexible production of different steel grades for various additive manufacturing applications.
3Productivity
If multiple induction furnaces are used for continuous production, then productivity increases, but device complexity increases
Solution Approach 1:
The system merges multiple induction furnaces into an integrated production line where molten steel from the blast furnace is distributed to multiple furnaces through a common refining system. The reservoirs and gas atomizers are configured to work in parallel, combining the output of multiple furnaces to achieve high continuous production capacity while sharing common infrastructure components.
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
Enables the production of steel powders with precise compositions and high versatility, supporting large-scale continuous production, meeting the demands of additive manufacturing by ensuring consistent quality and adaptability in steel composition.
Implementation Method 1
The temperature in the plurality of induction furnaces is maintained between 1500 and 1700° C.
Implementation Method 2
Feeding the at least one gas atomizer of each reservoir in molten steel from each reservoir under pressure and gas atomizing said molten steel to form the steel powder at the desired composition.
Implementation Method 3
Refining the molten iron in a converter to form molten steel comprising up to 600 ppm C, up to 120 ppm S, up to 125 ppm P, up to 50 ppm N and up to 1200 ppm O
Implementation Method 4
Providing molten iron from a blast furnace
Data Source
AI summary
A process for the production of steel powders including the steps of: providing molten iron from a blast furnace, refining the molten iron in a converter to form molten steel including up to 600 ppm C, up to 120 ppm S, up to 125 ppm P, up to 50 ppm N and up to 1200 ppm O, pouring the molten steel in a plurality of induction furnaces, adding, in each of the plurality of induction furnaces, at least one ferroalloy to adjust the steel composition, pouring the molten steel at the desired composition of each induction furnace in a dedicated reservoir connected to at least one gas atomizer, feeding the at least one gas atomizer of each reservoir in molten steel from each reservoir under pressure and gas atomizing the molten steel to form the steel powder at the desired composition.