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

高质量的粉末材料是许多增材制造工艺的要求，在热涂层、烧结和连接领域。在各自的工艺中使用粉末的机制研究，在特定材料和工艺条件下导致预期的结果，是理解和控制工艺的先决条件。然而，只有在可用的原料粉末也能以系统的变化提供和加工时，才有可能对这些机制进行系统的研究。这意味着全面工艺链设计的高度灵活的方法只能通过各自粉末原料的自由“设计”来实现，既不能由现有的市场供应提供，也不能通过商业委托提供的特殊粉末来提供。因此，以小批量但系统可变的批量生产高质量的粉末形式实验合金，对于上述粉末冶金工艺的综合研究和取得明显超越现有技术水平的研究成果具有重要意义。所提出的超声雾化制粉技术具有最适合这一目的的特点。高质量的粉末可以在惰性气体下小批量生产，同时具有高工艺可变性。除了坩埚支持的变体，棒雾化也是可能的。该系统的过程控制还允许加工非常广泛的材料，包括非反应性（例如钢）和反应性合金（例如基于Ti， Al, Zr），金属间化合物（例如非晶TiAl， NiAl, NiTi），具有耐火元素的合金，高温合金和贵金属。生产的粉末质量的特点是球形颗粒形状，高均匀性和低含量的杂质。颗粒直径可以在一个相关的直径范围内（大约）以可控的方式调整。20µm至120µm)，目标分数相关收率在50%至75%以上。在适合研究目的的实验室规模上，生产批次从几升到几公斤不等。因此，这些规格在很大程度上满足了大学部门的研究要求。此外，必要的、工厂专用的外围设备和必要的补充设备，在连接、电源要求、占地面积、工艺气体的任何需求等方面，与现场现有的技术水平相对应。

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..