Patent Application
20210114104
The present subject matter relates to advanced materials and, more particularly, to the production of metal powders for diverse applications, such as additive manufacturing for the aerospace and medical industries.
Water atomization uses water as an atomizing medium to atomize a molten stream of metal into very fine particles. Since water is an incompressible fluid, a high pressure jet provides both the density and the velocity required to produce fine powders at large production rates. However, water atomization has several limitations in terms of applications due to contamination from water, and the highly irregular and angular shape of the powder so produced.
As to gas atomization, it can produce metallic powders of high purity by hitting a molten stream with a high pressure inert gas jet. However, this method generally either results in a very low yield as to powders of finer size, or has a relatively low production rate. To achieve a good compromise between both these aspects, very high pressures are required to create a cold supersonic jet. Atomizing with cold gas has the down side of freezing the molten particles too rapidly, which causes gas entrapment within the particles, whereby such powders are less suitable for 3D printing applications, as it affects directly the density of the printed part. Also, due to a fast quenching rate, the shape of the particles is often spheroidal but not spherical. Satellite is also often a problem with this technology, as the large amount of gas used causes intense turbulence powder that forces the recirculation of the finer particles in the cooling chamber.
Turning to plasma atomization, it typically uses a wire instead of a molten stream as a feedstock, and uses a source of plasma (a.k.a. plasma torch) as the atomizing agent to break up the particles. Using a wire provides the stability required to ensure that the narrow plasma jets are aiming property at wire, since the wire has to be melted and atomized in a single step. This technology currently produces the finest, most spherical and densest powder on the market. In other words, the yield of powder produced in the 0-106 micron range is very high, sphericity is near perfect, and gas entrapment is minimized. However, this technology has two main disadvantages. First, dependence on wires as feedstock is significantly limiting, as some materials are too brittle to be made in the form of wire. Using a wire also implies adding cost to the feedstock material as ingots must be melted again so as to be extruded for producing the wire in question. The second major disadvantage is the much lower production rate in comparison to water atomization and to gas atomization. Reported production rates from plasma atomization companies are up to 13 kg/h. An expert in the field would recognize that a more realistic range for optimal particle size distribution would be much lower. For example, U.S. Pat. No. 5,707,419, which is entitled “Method of Production of Metal and Ceramic Powders by Plasma Atomization” and issued in the names of Tsantrizos et al. on Jan. 13, 1998, reports a feed rate of 14.7 g/min or 0.882 kg/h for titanium, while U.S. Patent Application Publication No. 2017/0326649-A1, which is entitled “Process and Apparatus for Producing Powder Particles by Atomization of a Feed Material in the Form of an Elongated Member” and which was published on Nov. 16, 2017 with Boulos et al. as inventors, discloses a reported feed rate of 1.7 kg/h for stainless steel.
Therefore, it would be desirable to provide an apparatus and a method for producing metallic powders from sources other than wires, and at a significant production rate.
It would thus be desirable to provide a novel apparatus and method for producing metallic powders from molten feedstock.
The embodiments described herein provide in one aspect an apparatus for producing metallic powders from molten feedstock, comprising:
a heating source for melting a solid feedstock Into a molten feed;
a crucible for containing the molten feed;
a delivery system to feed the molten feed as a molten stream; and
a plasma source adapted to deliver a plasma stream;
the plasma stream being adapted to be accelerated to a supersonic velocity and being then adapted to impact the molten stream for producing metallic powders.
Also, the embodiments described herein provide in another aspect a process for producing metallic powders from molten feedstock, comprising:
providing a molten feed;
delivering the molten feed as a molten stream;
providing a plasma stream;
accelerating the plasma stream to a supersonic velocity; and
impacting the molten stream with a supersonic plasma plume for producing metallic powders.
For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, which show at least one exemplary embodiment, and in which:
The present approach herein disclosed provides methods and apparatuses for producing metallic powders from sources other than wires, such as liquid or solid feedstock.
It is known that wires should be used in order to have a viable plasma-based atomization process. In the present subject matter, a supersonic plasma jet is used to atomize a molten stream, and there follows various embodiments related thereto.
A plasma atomization process that uses a wire ensures that the metal is in proper contact with the plasma jet to maximize heat and momentum transfer, such that the wire can be melted and atomized in a single step. However, there seems to be no physical reasons why the power required to melt continuously the metal should necessarily be provided by the plasma source. In gas and water atomizations, the melting and atomization are two distinct steps. This configuration allows greater production rates, as a result that the melting rate is not limited by the heat transfer and residence time between a supersonic jet and the feedstock.
The present subject matter provides a way to atomize a liquid feed using plasma jets, as in gas and water atomizations.
More particularly, a source of plasma, such as one or multiple plasma torches, is provided to deliver a plasma stream that can be accelerated to supersonic velocity prior to hitting the molten stream with high momentum.
The application of this concept is more complicated in practice than the previous statement may suggest, as supersonic plasma jets can hardly be contained since they create a very harsh environment for materials to survive.
For example, the melting point of Titanium alloy (Ti-6Al-4V) is around 1660° C. In order to provide a proper period of time for the liquid particle to reach a spherical shape, there is delivered a gas jet that is above the melting point of the material to be atomized. For Ti-6Al-4V, a jet temperature of around 1900° C. is preferred. On the basis that supersonic speeds convert thermal heat and pressure into Mach velocities, it is to be expected that the temperature drops significantly between before (upstream of) and after (downstream of) the throat of the supersonic nozzle. Accordingly, to get a Mach jet at 1900° C. at the apex (point of convergence between the plasma jet(s) and the molten stream to be atomized), a temperature above 2500° C. might be required at the inlet of the supersonic nozzle. Considering the heat losses of the high pressure and temperature chamber prior to the nozzle, it can be comfortably stated that the plasma source should have a plume temperature of above 3000° C. Commercial high enthalpy torches can provide this kind of temperature in a reliable way with commercially available spare parts.
Dealing with supersonic plasma jets in a confined area is always delicate. Due to the nature of these jets, there results a very harsh environment for materials to sustain, due to very high temperatures, thermal shocks and mechanical erosion. For this reason, proper materials should be chosen for the design of the plasma path from the torch to the apex. At temperatures above 3000° C., 1 to 2 Mach speed can represent 1500 m/s. Example of materials that can be used are graphite for the chamber, and for the nozzle hard refractory elements that have very high melting point as well as their carbides, such as tungsten, tungsten carbide, titanium carbide, hafnium, hafnium carbide, Niobium, Niobium carbide, tantalum, tantalum carbide, molybdenum, molybdenum carbide, etc. It is also preferable to operate under an inert atmosphere, not only for the quality of the powder produced (to reduce its potential for oxidation), but also to help the survival of the high temperature materials mentioned hereinabove.
The source of plasma stream can come from a single source or a combination of multiple sources, as detailed hereinafter.
With reference to
More particularly,
In
Now turning to
For each of the above-described apparatuses A, A′ and A″, in the horizontal axis, it is suggested for the supersonic jets to be aimed with an angle that pushes downward the molten stream (jet).
The molten stream can be obtained from rods or ingot as well as from other sources. The technique(s) used to melt the solid feedstock into a molten stream and to bring the same to the apex zone is irrelevant as long as the appropriate velocity, pressure and temperature are provided by such technique(s).
In the present exemplary embodiments, the plasma source is an arc plasma torch because of its common availability. However, many other ways for achieving the thermal plasma state could be used. For example, inductively-coupled, microwave, and capacitive plasma sources could be used as well.
Another interesting aspect of the present subject matter resides in that, since the gas and/or plasma has such a high temperature at the inlet of the supersonic nozzle, much lower pressures are required to reach Mach speed. Such lower pressures significantly reduce the cost of the installation and the thickness required for the parts. For the exemplary embodiments mentioned hereinabove, an inlet of 10 atm is sufficient to feed the entire setup, while fine particle gas atomization often uses pressures in the order of magnitude of the 40-450 atm.
While the above description provides examples of the embodiments, it will be appreciated that some features and/or functions of the described embodiments are susceptible to modification without departing from the spirit and principles of operation of the described embodiments. Accordingly, what has been described above has been intended to be illustrative of the embodiments and non-limiting, and it will be understood by persons skilled in the art that other variants and modifications may be made without departing from the scope of the embodiments as defined in the claims appended hereto.
This Application claims priority on U.S. Provisional Application No. 62/644,459, now pending, filed on Mar. 17, 2018, which is herein incorporated by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2019/000034 | 3/18/2019 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62644459 | Mar 2018 | US |
