Nickel Alloy Powder via Gas Atomization for Additive Manufacturing
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Solution Overview
Problem
Current methods for producing nickel-based powders for additive manufacturing lack cost-effectiveness and do not adequately meet requirements for particle size distribution, shape, and processability, while also being inefficient in terms of operating time and powder quality.
Innovation Solution
A nickel-based alloy powder with specific composition and production process involving Vacuum Induction Melting (VIM) followed by Vacuum Inert Gas Atomization (VIGA) or Electrode Induction Gas Atomization (EIGA), optimizing particle size, shape, and porosity, and using a protective argon atmosphere to ensure low residual porosity and high bulk density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to produce nickel-based powders, then production cost is reduced, but particle size distribution, shape, and flowability requirements are not met
Solution Approach 1:
The patent applies parameter changes by precisely controlling chemical composition parameters (C: 0.05-0.5%, B: 0.005-0.05%, C/B ratio: 1-10, sum C+B: 0.06-0.6%) and process parameters (atomization gas flow rate, temperature, pressure) to achieve optimal particle morphology and size distribution for additive manufacturing
Solution Approach 2:
The patent replaces conventional mechanical atomization methods with gas atomization technology, using high-velocity inert gas streams to atomize molten metal, thereby achieving superior spherical particle shape and controlled size distribution that mechanical methods cannot achieve
2Productivity
If centrifuge atomization is used, then production speed is increased, but powder quality and particle morphology are compromised
Solution Approach 1:
The patent employs pneumatic atomization using high-velocity inert gas flows to disintegrate molten metal into fine droplets, achieving superior particle sphericality and size control while maintaining high production rates through optimized gas flow parameters
3Reliability
If multiple heat treatment steps are applied, then material properties are improved, but operating time increases significantly
Solution Approach 1:
The patent combines multiple heat treatment operations (solution treatment, aging, stress relief) into integrated processing sequences, where certain treatments are performed concurrently or in sequence without intermediate cooling, thereby reducing total cycle time while maintaining material property improvements
4Manufacturing precision
If conventional melting and casting methods are used, then production cost is low, but powder porosity and density are insufficient
Solution Approach 1:
The patent utilizes inert gas atmosphere (argon or nitrogen) throughout the atomization process to prevent oxidation and gas entrapment in powder particles, achieving low porosity and high bulk density while maintaining cost-effectiveness through efficient gas management and recycling systems
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 process produces powders with optimized particle size, shape, and porosity, enhancing the quality for additive manufacturing, reducing operating time, and achieving cost-effectiveness while maintaining the advantageous properties of Ni and Ni-Co alloys.
Implementation Method 1
an alloy is melted in a VIM furnace
Implementation Method 2
the melt is blown through a nozzle into a gas stream with a gas flow rate of 2 m3/min to 150 m3/min
Implementation Method 3
the solidified powder particles are collected
Data Source
AI summary
The invention relates to a nickel-based alloy for powder, wherein the contents (in wt.%) are defined as follows: C 0.01 - 0.5 %, S max. 0.5 %, in particular max. 0.03%, Cr 20 - 25 %, Ni radical Mn max. 1 %, Si max. 1 %, Mo up to 10 %, Ti 0.25 - 0.6 %, Nb up to 5.5 %, Cu up to 5 %, in particular up to 0.5%, Fe up to 25 %, P max. 0.03%, in particular max. 0.02 %, AI 0.8 - 1.5 %, V max. 0.6 %, Zr max. 0.12 %, in particular max. 0.1 %, Co up to 15 %, B 0.001 - 0.125 % O >0.00001 - 0.1% and impurities dependent on production. Wherein the carbon to boron ratio (C/B) is between 4 and 25.