High-Purity Powder Production Through Two-Phase Impurity Separation
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Solution Overview
Problem
Conventional atomization comminuting processes are costly and inefficient for producing ultrafine metal powders with particle sizes below 10 μm, and they struggle with impurity control, particularly oxygen impurities, making high-purity metal powders difficult and expensive to obtain.
Innovation Solution
A method involving the preparation of an initial alloy melt, followed by atomization and solidification to create an intermediate alloy powder with a first phase enriched in impurities in a second-phase matrix, allowing for the removal of the matrix to obtain high-purity first-phase particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional atomization comminuting process is used to produce ultrafine metal powders, then particle size can be reduced below 10 μm, but production cost becomes extremely high
Solution Approach 1:
The patent divides the alloy melt into two distinct phases during solidification: a first phase containing the target metal and a second phase matrix containing impurities. This phase segmentation allows selective removal of the impurity-rich matrix while retaining the target metal particles, achieving ultrafine particle size without the extremely high costs of conventional single-phase atomization processes.
Solution Approach 2:
The patent extracts the second phase matrix (containing impurities) from the intermediate alloy powder through selective removal processes such as acid dissolution, alkali treatment, or vacuum heating. This extraction leaves behind purified first phase particles with controlled ultrafine size, eliminating the need for expensive conventional ultrafine powder production methods.
2Manufacturing precision
If conventional atomization comminuting process is used to obtain high-purity metal powders, then impurity content can be reduced, but production cost increases greatly
Solution Approach 1:
The patent segments impurity elements into a separate second phase matrix during solidification, physically separating them from the first phase containing the target metal. This automatic impurity segregation achieves high purity without requiring expensive high-purity raw materials or complex purification processes.
Solution Approach 2:
The patent converts the harmful effect of impurity elements during solidification into a beneficial separation mechanism. Impurities are deliberately allowed to concentrate in the second phase matrix, which is then selectively removed. This transforms the problem of impurity control into an advantage for purification, reducing both cost and complexity.
3Length of moving object
If conventional atomization comminuting process is used to produce sub-micron and nanopowders, then particle size below 1 μm can be obtained, but the process becomes difficult to implement
Solution Approach 1:
The patent utilizes phase transition during solidification to create a two-phase structure from a homogeneous alloy melt. The first phase (target metal) and second phase (matrix with impurities) form through controlled solidification, enabling subsequent separation. This phase transition approach simplifies the process compared to direct mechanical size reduction methods.
Solution Approach 2:
The patent changes the compositional parameters of the initial alloy to enable formation of the two-phase structure. By carefully selecting the alloy composition and controlling solidification conditions, the process achieves ultrafine particle sizes through phase separation rather than complex mechanical comminution, reducing device and process complexity.
4Manufacturing precision
If high-purity metal raw materials are used with strict impurity control during smelting and atomization, then high-purity metal powders can be obtained, but preparation cost is greatly increased
Solution Approach 1:
The patent allows impurity elements to be intentionally introduced during smelting and atomization, then converts this previously harmful effect into a beneficial separation mechanism. The impurities automatically concentrate in the second phase matrix during solidification, which is subsequently removed. This eliminates the need for expensive high-purity raw materials and strict impurity control measures.
Solution Approach 2:
The patent implements self-service purification through the solidification process itself. The two-phase structure forms automatically during cooling, with impurities self-segregating into the matrix phase. This self-organizing separation eliminates the need for external high-purity material inputs or complex purification equipment, greatly reducing preparation cost.
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
This method effectively purifies ultrafine metal powders by enriching impurities in the second phase, enabling the production of high-purity target powders with controlled particle sizes and shapes, reducing production costs.
Implementation Method 1
atomizing and solidifying the initial alloy melt through an atomization comminuting process
Implementation Method 2
atomizing and solidifying the initial alloy melt through an atomization comminuting process
Implementation Method 3
impurity elements in the initial alloy melt and introduced during an atomizing solidification process are enriched in the second-phase matrix such that the first-phase particles are purified
Implementation Method 4
removing the second-phase matrix in the intermediate alloy powder, and retaining the first-phase particles, wherein the impurity elements enriched in the second-phase matrix are removed together with the second-phase matrix
Data Source
AI summary
The present disclosure provides a method for preparing a high-purity powder material, an application thereof, and a double-phase powder material. The high-purity powder material is prepared through an “atomization comminuting process and de-phasing method”. The preparation method comprises the following steps: firstly preparing intermediate alloy powders with first-phase particles wrapped by a second-phase matrix through an atomization comminuting process. Impurity elements are enriched into the second-phase matrix and the first-phase particles are purified during the solidification of the intermediate alloy powders; By removing the second-phase matrix in the intermediate alloy powders, a high-purity target powder material originated from the original first-phase particles can be obtained. The preparation method of the present disclosure has the characteristics of a simple process, easy operation, and low cost, and can be used to prepare nano-level, sub-micron-level, and micro-level multiple high-purity powder materials, which has a good application prospect in catalytic materials, powder metallurgy.