technology allows for 3D printing. Its most notable advantage is the ability to generate parts in any shape directly from computer graphics data, without any machining and molds. This greatly reduces the product development cycle while increasing productivity and reducing costs. Metal powder, the main raw material in 3D printing of metal components, has caught people’s interest. 3D Printing Metal Powder is the most valuable and important part of 3D Printing Industry Chain of Metal Parts.

Metal powder preparation process

The metal powder preparation processes can currently be classified as reduction, electrolysis and carbonyl decomposition methods, grinding and atomization. The preparation method is divided into reduction, electrolysis, carbonyl decomposition, grinding and atomization. In the powder metallurgy sector, powders produced by reduction, atomization, and electrolysis are the most commonly used raw materials. The atomization technique can be used to make alloy powder and modern atomization can also control powder shape. The development of the atomization cavities has greatly improved the efficiency of atomization, making the atomization technique the most popular method to produce powder. The atomization technique meets the specific requirements of 3D printed consumable metals powder. The atomization process is a mechanical method for pulverizing the molten metal to particles smaller than 150mm.

Water atomization

The water atomization process is a low-cost method for producing powder atomized. The atomization media water is cheap and easy to get, but it also provides excellent atomization. The domestic water atomization technique is used primarily for the production of steel powder, matrix for diamond tools and pre-alloys for oil-bearing rollers. It’s also used for powders for hard surface technologies, iron-based and Nickel-based magnetic powders. The specific heat of water being much greater than the gas’s, it is possible that the metal droplets will solidify and become irregular during the atomization. Water will react with other metals or alloys that have a high level of activity. In addition, contact with the water during the atomization will increase the amount of oxygen in the powder. This limits the use of water atomization for metal powders of high sphericity with low oxygen contents.

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Gas atomization, or gas atomization, is a method used to create metal alloy powders. Gas atomization works by breaking up the liquid metal stream with high-speed airflow into small drops and then solidifying it into powder. Powder preparation has been a major development area for special alloy and high-performance powders due to its benefits of high purity and low oxygen content. It also offers controllable particle size, low cost, and high sphericity. The following are some representative gas atomization techniques for powder production:
Laminar atomization flow technology

The German company etc. proposed the laminar atomization technique. This technology offers significant improvements over conventional nozzles. The atomizing nozzle is characterized by high atomization efficiency and narrow powder particle distribution. It also has a cooling speed between 106-107K/s. The copper, aluminum and 316L stainless-steel, etc., can be atomized under a 2.0MPa atomization force. Ar or Nitrogen is used to atomize the powder, with an average particle diameter of 10mm. It is a process that produces most metal powders and has a low gas usage. The technical control of this process is difficult. It is also unstable. And the output (metal mass flow rate less than 1kg/min), is low. This is not suitable for industrial production.
Ultrasonic tightly combined atomization technology

Close-coupled atomization using ultrasonic technology improves the design of a ring-slot nozzle to increase the flow rate and mass of metal. When atomizing high-surface energy metals like stainless steel, the average size of the particles can reach around 20mm and the standard deviation can be as little as 1.5mm.

The technology can be used to produce amorphous, fast cooling powder or powder that is cooled quickly. The current development of this equipment shows that it is the next step in the development of tightly coupled technology. It can be applied to a wide range of materials such as alloy powders and micro stainless steel.

Hot gas atomization

A US company has been conducting extensive research in recent years to determine the mechanism and effect of hot-gas atomization. In the United States, a company heated gas to 200-400degC under pressure of 1.72MPa to atomize the silver alloy and gold alloy. It found that the particle size and standard deviation decreased as the temperature increased. The hot gas atomization process is more efficient than traditional atomization, consumes less gas, and can be easily implemented on conventional atomization machines. This is a promising technology.

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Currently, 3D printing metal powder materials include stainless steel, die steel, nickel alloys, titanium alloys, cobalt-chromium alloys, aluminum alloys and bronze alloys.
Iron-based alloys are the most commonly used metal material in engineering technology. They are most commonly used to create complex structures, such 3D-printed stainless steel. This technology is more durable than traditional casting or forging, and it can withstand high temperatures and wear well. It has excellent dimensional accuracy, material utilization, and chemical resistance. It is extensively used in aerospace and machine manufacturing as well as shipbuilding and automotive.

Titanium alloy’s strength and toughness are combined with low specific gravity and corrosion resistance. It is ideal for high-performance aerospace and automotive engineering applications. It is also used for the manufacture of biomedical implant, which are high-modulus, low modulus, and have strong fatigue resistance.

Cobalt and chrome alloys are often used in surgical implant applications such as alloy knee joints, alloy hip joints, and all-alignment artificial joints. This is due to their high wear resistance and biocompatibility.

Aluminum alloy is one of the most popular non-ferrous metals structural materials in industry. It is light in density, strong and flexible. 3D printing of aluminum alloys has been shown to produce parts with dense structures and mechanical properties comparable or even better than casting molded. They can achieve a 22% reduction in quality, while the cost of traditional process parts can be cut by 30%.

Copper alloys exhibit excellent electrical and thermal conductivity. The excellent thermal conductivity of copper in thermal management applications allows for design freedom and the ability to produce intricate internal structures as well as conformal cooling channels.
You can divide the metal powder preparation methods into electrolysis, reduction, grinding and atomization. depending on the preparation method. The two most common powder-making methods in China at the moment are the argon and plasma rotating electrode.

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