Inert gas atomization system

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The subject of the present application is a complete system for the production, characterization and classification of spherical metal powders. For this purpose, an inert gas atomization system as well as corresponding components for characterization and classification are applied for. The system is intended to close the existing gap between the research fields of alloy development and powder metallurgical processing, both of which are already well established at the LWT and the RUB. A proprietary metal powder forming process will enable the adequate addressing of innovative material and alloy concepts in the current research fields of powder metallurgy, which is only possible if a complete process chain is taken into account.The facility applied for here enables an integrated research approach that covers the whole powder formation process. It entails scientific materials investigations, target-oriented alloy development, optimization of the atomization process technology and further processing of the metal powders. Facilitated by the interdisciplinary collaboration of several departments a multi-scale approach from microstructure to component is taken to represent and optimize the material along its process chains. For example, thermodynamic simulations are used to optimize alloy concepts via neural networks, which determine the powder particle formation in terms of melt viscosity, solidification and oxidation behavior. In addition, solidification and structure formation processes of the metal powders and their properties are simulated on a microstructural scale in order to gain a deeper understanding of the processing and metallurgical interactions. Process parameters can thus be evaluated in preliminary steps. Following powder production, the powders are characterized using microscopic and macroscopic methods. In this way, simulation results are validated, understanding is deepened and utilized for alloy design. Further on, powders are produced targeting specific properties, which ultimately results in finished components with innovative mechanical, chemical or physical properties and, which is, at the same time, particularly economical and sustainable due to low material losses.