Laboratory devise for the production of metallic and intermediate powders by ultrasonic atomisation

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High-quality powder materials are a requirement for numerous processes of additive manufacturing, in the field of thermal coating, sintering and joining. The research of mechanisms in the use of powders in the respective processes, which lead to the intended result in the presence of the specific materials and process conditions, is a prerequisite for the understanding and control of the process. However, systematic research of these mechanisms is only possible if the available feedstock powder can also be provided and processed in a systematically variation. The highly flexible approach for a comprehensive process chain design that this implies is only possible through a free "design" of the respective powder feedstock and can neither be served by the available market supply nor by commercially commissioned provision of special powders. Consequently, the production of high-quality experimental alloys in powder form in small but systematically variable batches is of great importance for the comprehensive research of the powder metallurgical processes mentioned and the achievement of research results that clearly go beyond the existing state of the art. The proposed technology of powder production by ultrasonic atomisation has the most suitable characteristics for this purpose. High-quality powders can be produced under inert gas in small batches with simultaneously high process variability. In addition to the crucible-supported variant, rod atomisation is also possible. The process control of the system also allows the processing of an extremely wide range of materials, including non-reactive (e.g. steels) and reactive alloys (e.g. based on Ti, Al, Zr), intermetallic compounds (e.g. amorphous TiAl, NiAl, NiTi), alloys with refractory elements, superalloys and precious metals. The powder qualities produced are characterised by a spherical particle shape, high homogeneity and a low content of impurities. The particle diameters can be adjusted in a controlled manner in a relevant diameter range (approx. 20 µm to 120 µm) with target fraction-dependent yields between 50 % and over 75 %. A production batch ranges from a few litres to a few kilograms on a laboratory scale suitable for research purposes. These specifications thus meet the research requirements in the university sector to a high degree. In addition, the necessary, plant-specific peripherals and the necessary supplementary equipment correspond to the state of the art available at the site with regard to connections, power requirements, floor space, any need for process gases, etc..