Metal Powder Preparation Using Short-Circuit Arc Atomization
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Solution Overview
Problem
Existing powder preparation processes, such as electrode induction melting gas atomization (EIGA) and electric arc processes, consume excessive energy, are difficult to implement, and fail to achieve a satisfactory control over particle size distribution, requiring additional steps and increased costs to meet user requirements.
Innovation Solution
A process utilizing a short circuit current with specific voltage and frequency ranges, combined with inert gas atmosphere and controlled material dispensing, to form droplets that are cooled and enriched with active substances, resulting in a controlled particle size distribution and improved material quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electrode induction melting gas atomization (EIGA) or conventional electric arc processes are used, then spherical metal powders can be obtained with limited material pollution, but energy consumption is excessive and implementation becomes difficult
Solution Approach 1:
The invention changes the electrical parameters by using a short circuit current regime with specific voltage (10-30 V) and frequency (40-200 Hz) ranges, replacing conventional high-energy continuous arc processes. This parameter modification enables controlled droplet formation and solidification while significantly reducing energy consumption.
Solution Approach 2:
The invention employs periodic short circuit current pulses at frequencies between 40-200 Hz to create controlled melting and droplet ejection cycles. This periodic action allows precise control over particle formation timing and size distribution, replacing continuous high-energy processes.
2Manufacturing precision
If conventional electric arc processes are used, then melting and spraying can be achieved, but particle size distribution is not sufficiently controlled requiring additional separation steps
Solution Approach 1:
The invention implements feedback control by monitoring the short circuit current characteristics and adjusting the process parameters accordingly. The electrical parameters (voltage 10-30 V, frequency 40-200 Hz) are controlled based on feedback from the melting and droplet formation process, enabling precise particle size distribution control without additional separation equipment.
3Manufacturing precision
If high velocity pulsed gas stream is used for atomization, then fine powder particles can be formed, but the process becomes complex and energy-intensive
Solution Approach 1:
The invention replaces the complex mechanical high-velocity gas atomization system with an electrical field-based short circuit current process. The electrical current directly creates and controls droplet formation and solidification, eliminating the need for complex gas delivery and velocity control systems while maintaining precise particle size control.
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 achieves better control over particle size distribution, reduces energy consumption, minimizes oxidation, and ensures compliance with industry standards like ASTM F3001-14 and ASTM F2924-14, while maintaining material composition integrity.
Implementation Method 1
a step of melting the first and second materials, using an electric arc formed by the application of an electric current between said first and second materials
Implementation Method 2
melting the material from a slowly rotating metal rod using a high-frequency induction coil
Implementation Method 3
a step of cooling the droplets by means of a carrier gas so as to form solid particles
Implementation Method 4
a step of spraying the first and second molten materials in such a way as to form droplets
Data Source
AI summary
A preparation process for preparing powder from a first material and a second material, having a step of melting the first and second materials using an electric arc, a step of spraying the first and second molten materials in such a way as to form droplets, a step of cooling the droplets using a carrier gas so as to form solid particles, and a step of separating the solid particles from the carrier gas and collecting the solid particles so as to form the powder, the electric current applied to form the electric arc being a short circuit current.