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

高质量的粉末材料是增材制造的许多工艺的要求，在热涂层，烧结和连接领域。在特定的材料和工艺条件下，对粉末在各个工艺中的使用机制进行研究，从而达到预期的结果，这是理解和控制工艺的先决条件。然而，这些机制的系统研究是唯一可能的，如果可用的原料粉末也可以提供和处理在一个系统的变化。这意味着只有通过对相应粉末原料的自由“设计”，才能实现高度灵活的综合工艺链设计，既不能通过市场供应，也不能通过商业委托提供特殊粉末。因此，以小批量但系统可变的批量生产高质量的粉末状实验合金，对于上述粉末冶金工艺的综合研究和取得明显超出现有技术水平的研究成果具有重要意义。所提出的超声雾化粉末生产技术具有最适合此目的的特性。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。该系统的工艺控制还允许加工范围极广的材料，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）、含难熔元素的合金、超级合金和贵金属。所生产的粉末质量的特征在于球形颗粒形状、高均匀性和低杂质含量。颗粒直径可以在相关直径范围内（约100微米）以受控方式调节。20 µm至120 µm），目标馏分依赖产率在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，必要的工厂专用外围设备和必要的辅助设备在连接、电源要求、占地面积、工艺气体需求等方面符合现场现有的最新技术水平。

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..