Wire Arc Powder Manufacturing for Oxygen and Particle Size Control
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Solution Overview
Problem
Existing powder manufacturing processes, such as the EIGA process and the process described in EP4221916A1, consume significant energy, are difficult to implement, and do not allow for precise control of the oxygen content or composition of the manufactured powders, particularly failing to meet user-specific oxygen content requirements.
Innovation Solution
A process involving the distribution of first and second wires made of specific materials, melting them with an electric arc, spraying the molten materials to form droplets, cooling with a carrier gas, and separating and collecting the solid particles, with additional steps for enrichment and analysis, using active substances and controlled electric current to manage oxygen content and particle size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high-frequency induction coil melting is used (EIGA process), then spherical metallic powders with limited contamination are obtained, but energy consumption is high and implementation is difficult
Solution Approach 1:
The patent replaces the high-frequency induction coil melting system with a gas flame melting system. Instead of using electromagnetic induction to melt the wire, a gas flame (such as oxy-acetylene or oxy-propane) is used to heat and melt the wire at the tip, which then forms droplets that are atomized into powder. This substitution significantly reduces energy consumption while maintaining powder quality.
2Productivity
If electric arc melting with carrier gas cooling is used (EP 4 221 916 A1), then powder production is achieved, but oxygen content cannot be precisely controlled
Solution Approach 1:
The patent introduces an inert or controlled atmosphere system using gases such as argon, nitrogen, or carbon dioxide. The wire feeding path, melting zone, and atomization chamber are purged and maintained under controlled atmospheric conditions to prevent oxidation of the molten metal and resulting powder. This allows precise control of oxygen content in the produced powder, addressing the limitation of previous electric arc methods.
3Device complexity
If wire is fed directly to electric arc without additional means, then process is simple, but wire distribution control and oxygen content are insufficient
Solution Approach 1:
The patent introduces intermediary components between the wire feed and the melting zone, including a wire guide, protective atmosphere system, and controlled feeding mechanism. These intermediaries protect the wire from oxidation during feeding, control the wire delivery rate, and maintain proper positioning at the melting zone, thereby improving both wire distribution control and oxygen content management without significantly complicating the overall process.
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 lower oxygen content in the powders, better control over particle size distribution, and improved chemical composition, meeting specifications like ASTM F3001-14 and ASTM F2924-14, while reducing energy consumption and mechanical stress on the wires.
Implementation Method 1
a step of melting the first and second materials by means of an electric arc formed by the application of an electric current between said first and second materials
Implementation Method 2
melting the first and second materials by means of an electric arc formed by the application of an electric current
Implementation Method 3
a step of cooling the droplets by means of a carrier gas so as to form solid particles
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a method for manufacturing (100) powder (5) from a first material (1a) and a second material (1b), comprising: a step of distributing the wires (312a, 312b) of the materials (1a, 1b) with a winding means (1000) and an additional winding means (2000), a step of melting (110) the wires, a step of spraying (120) so as to form droplets (2), a step of cooling (130) the droplets (2) so as to form solid particles (3), a step of separating the solid particles from the carrier gas (11) and collecting (140) the solid particles (3) so as to form the powder (5), and during said distribution step the wires (312a, 312b) are first pushed by said winding means (1000) and then pulled by said additional means (2000), then pushed by said additional means (2000) towards said electric arc (314).