Spherical Metal Powder Formation via Arc Plasma and Fluid Quenching
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Solution Overview
Problem
Existing methods for preparing metallic powders face challenges such as high porosity, micro-cracks, and irregular particle shapes, leading to poor mechanical properties and increased costs, particularly in 3D printing applications.
Innovation Solution
A method involving arc plasma generation with a controlled fluid medium to melt and explode material, forming fine spherical powders with controlled rotation and flow rates, followed by collection and refinement to achieve uniform particle size and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas atomization method is used to prepare metallic powder, then the process is mature and stable with small particle size and fine structure, but hollow powder and satellite powder increase porosity and micro-cracks in parts
Solution Approach 1:
The patent extracts and removes hollow powder and satellite powder from the particle population through classification processes. This selective removal eliminates the harmful factors that cause porosity and micro-cracks while retaining the beneficial fine particle size distribution from gas atomization
Solution Approach 2:
The patent changes the morphological parameters of particles by controlling atomization conditions, classification thresholds, and processing parameters to transform hollow and satellite particles into dense spherical particles with controlled size distribution, thereby improving part density
2Reliability
If rotating electrode method is used to prepare metallic powder, then there are very few hollow powder and satellite spheres with dense molding, but the cost of powder preparation is high and particle size is larger
Solution Approach 1:
The patent replaces the complex mechanical rotating electrode system with a simpler gas atomization system combined with classification processes. This substitution achieves similar or better particle quality (reduced hollow powder) while significantly lowering preparation costs and enabling smaller particle sizes
Solution Approach 2:
The patent introduces classification processes as an intermediary step between atomization and final powder production. This intermediary mechanism selectively separates and removes hollow and satellite particles, achieving the quality benefits of rotating electrode method while maintaining the cost and size advantages of gas atomization
3Strength
If gas atomized powder is used in additive manufacturing, then the process is mature with small particle size conducive to mechanical properties, but hollow powder and satellite powder increase porosity risk
Solution Approach 1:
The patent converts the harmful effect of hollow and satellite powder (which cause porosity) into a beneficial classification criterion. By using these abnormal particles as indicators for classification and removal, the process ensures high particle density and spherical morphology, which directly improve mechanical properties while eliminating porosity risks
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 method produces metallic powders with small, uniform particle sizes, high sphericity, low hollow and satellite content, and improved flowability, enhancing processing efficiency and mechanical properties.
Implementation Method 1
adjusting a discharging gap between the electrode and the workpiece by a motion control system to generate an arc plasma, when the arc plasma acts on surfaces of the electrode and the workpiece, the surfaces of the electrode and the workpiece are melted
Implementation Method 2
the surfaces of the electrode and the workpiece are melted, to form a melting region
Implementation Method 3
condensing the crushed molten material in the fluid medium, and collecting a condensed fine spherical powder
Implementation Method 4
condensing the crushed molten material in the fluid medium
Data Source
AI summary
Disclosed is a spherical powder, and a preparation method therefor including: placing an electrode and a workpiece at two electrodes of a power supply, adjusting a discharging gap between the electrode and workpiece by a motion control system to generate an arc plasma, when arc plasma acts on surfaces of the electrode and workpiece, the surfaces of the electrode and workpiece are melt to form a melting region, at the same time, introducing a fluid medium into the discharging gap, controlling a flow rate of the fluid medium and a relative rotation speed of the electrode or the workpiece, so as to change a working morphology of the arc plasma, such that a tiny explosion is generated in the melting region, crushing and throwing away a material located in the melting region, condensing the crushed molten material in the fluid medium and collecting a condensed fine spherical powder.