Understanding Powder Atomization Equipment

Table Of Contents 

Powder atomization is a mechanical process used to produce fine powders from molten
metal. It involves breaking up a molten metal stream into fine droplets which solidify
into powder particles. Atomization produces spherical metallic powders with controlled
particle size distribution. This overview examines the key aspects of powder
atomization equipment.

Powder Atomization Equipment Types

There are several main types of atomization equipment used in industrial powder
production:

Equipment Description

Molten metal stream atomized by high pressure inert gas

Gas atomization
jets

Molten metal stream broken up by high pressure water

Water atomization
jets

Centrifugal
Molten metal poured or driven off edge of spinning disc
atomization
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 Equipment Description

Plasma atomization Plasma arc melts and atomizes metal into fine droplets

Gas atomization and water atomization are the most common industrial methods.
Centrifugal, ultrasonic and plasma atomization have more specialized applications. The
choice depends on factors like material being atomized, powder specifications required,
production rate and cost.

Atomization Process Characteristics

Key characteristics of the powder atomization process using different methods:

Characteristic Typical Range

Gas pressure 2-8 MPa

Water pressure 10-150 MPa

Gas flow rate 0.5-3 m3/min/mm2

Disc diameter 100-1000 mm

Disc speed 10000-50000 rpm

Frequency 20-60 kHz

Plasma power 30-80 kW

Higher gas and water pressures produce finer powder particles. Faster disc speeds and
higher frequencies also create finer powders. The ranges reflect industrial practice for
common metals like steel, aluminum, copper alloys.

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 Powder Particle Size Control

Particle size distribution is a critical quality metric for atomized powders. The main
factors controlling powder particle size are:

Atomizing fluid pressure – higher pressure creates finer particles

Atomizing fluid flow rate – higher flow gives finer particles
Molten metal flow rate – lower metal flow yields finer powder
Atomizing nozzle design – nozzle geometry affects droplet size
Disc/nozzle relative velocity – faster relative motion makes smaller droplets
Material properties – viscosity, surface tension affect fragmentation

Careful control of these parameters allows production of powder with target particle
size distribution. For example, gas atomized steel powder with D50 of 10-100 microns.
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Applications Of Atomized Metal Powders
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 Atomized powders find uses in many industries and applications:

Industry Applications

Powder metallurgy Press and sinter components, MIM feedstock

Metal additive manufacturing Binder jet printing, DED feedstock

Thermal spray coatings Wire-arc, plasma, flame spray coatings

Welding Flux cored arc welding filler

Brazing Braze pastes and preforms

Electronics Conductive pastes and inks

Automotive Friction materials, powder forging

Spherical atomized powders provide excellent flowability and mixing needed for many
powder processing methods. Tight control of powder size distribution optimizes
performance.

Powder Atomization System Design

Key elements in designing an atomization system are:

Metal delivery – Tundish, pouring vat, induction guide or rotating electrode

Atomizer – Nozzle design, number of nozzles, nozzle placement
Atomizing medium – Gas control manifold, water pumps and plumbing
Powder collection – Cyclone separators, bag house filters, scrubbers
System controls – Pressure, temperature and flow sensors and control loops

Additional considerations are containment, safety interlocks, powder handling and

storage. Systems can be custom engineered to produce most metal alloys.

Specifications For Atomization Equipment

Typical specifications for industrial gas and water atomization systems:

Parameter Typical Ranges

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 Parameter Typical Ranges

Atomizing gas pressure 2-8 MPa

Atomizing gas flow 0.5-3 Nm3/mm2

Water pressure 10-150 MPa

Nozzle size 2-8 mm ID

Nozzle type Straight bore, convergent-divergent

Cyclone efficiency >95% at 10 μm

Baghouse efficiency >99.9% at 1 μm

Capacity, pressure, and nozzle details depend on alloy, desired particle sizes and
production rates. System is custom designed for specific application.

Installation And Operation

Important considerations for installing and operating powder atomization equipment:

Proper foundations and supports for dynamic equipment

Vibration isolation to minimize transfer to structures
Robust interlocks on gas, water, electrical systems
Monitoring and control instrumentation for process variables
Containment of overspray and dust in work zones
Fume and dust extraction equipment operation
Safety protocols for molten metal handling and spray
Calibration and maintenance of gas/water systems
Shutdown and cleanout procedures to prevent buildup

Startups should follow carefully developed procedures. Staff training is critical to safely
operate and maintain the system.

Maintenance Requirements

Routine maintenance is needed for optimal uptime and powder quality:

Inspect atomizing nozzles – replace worn or damaged nozzles

Check spin
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Verify calibration of pressure, flow and temperature sensors
 Check operation of emergency stop valves and interlocks
Monitor atomizing gas purity – moisture can cause oxidation
Clean feed lines and tundish to avoid metal buildup
Lubricate and inspect spin drive motor and bearings

Establish maintenance schedule and procedures based on hours of operation and

criticality.

Choosing An Atomization Equipment Supplier

Key factors in selecting an atomization system supplier:

Experience with specific alloy being atomized

Capability to engineer full system
Range of available nozzle designs and atomizer configurations
Flexibility to meet capacity and particle size needs
Installation, training, and aftersales support offered
Local presence or partnerships in target market
Compliance with applicable codes and standards
References and case studies for similar projects
Pricing and delivery timeline

Evaluate suppliers based on technical expertise, not just equipment cost. An

experienced partner helps ensure success.

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 Cost Analysis Of Atomization Systems

Atomization equipment has high capital cost but can produce powder at competitive
pricing:

System Capital Cost Range Powder Price Range

Gas atomization $500,000 – $5,000,000 $5-50/kg

Water atomization $200,000 – $2,000,000 $2-20/kg

Centrifugal atomization $50,000 – $500,000 $10-100/kg

Ultrasonic atomization $100,000 – $1,000,000 $50-500/kg

Plasma atomization $200,000 – $2,000,000 $20-200/kg

Costs driven by capacity, materials of construction, controls. Fine powders command

premium pricing. Require high production volume to justify capital investment.

Pros And Cons Of Powder Atomization Methods

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 Method Advantages Disadvantages

Narrowest particle distribution, High capital cost, high gas

Gas atomization
inert atmosphere consumption

Water Lower equipment cost, small Oxidation possible, drying

atomization particle sizes required

Centrifugal Broad particle distribution,

Simple design, easy scale up
atomization irregular shapes

Ultrasonic No fluids required, low Limited alloys and production

atomization maintenance rate

Plasma Very fine particles from pure High energy use, low powder
atomization metal output

Select method based on priority factors like particle size, atmosphere, cost, alloy
compatibility. No single best option for all scenarios.

Key Takeaways On Powder Atomization Technology

Wide range of equipment options to produce fine metal powders from molten
alloys
Gas and water atomization most common; specialized techniques available
Control of fluid and metal flow dynamics governs final particle sizes
Spherical powders with optimized particle distribution enable advanced
applications
Significant capital investment required but powder pricing can support it
Partnering with experienced supplier critical for successful atomization project

Careful process development and engineering produces powder with characteristics to

match application needs.

Powder Atomization Equipment FAQ

Q: What metals and alloys can be atomized into powder?

A: Most standard steels, aluminum alloys, copper alloys, nickel superalloys can be
atomized.
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Q: What are typical gas atomization pressures and flow rates?
 A: Gas pressures range from 2-8 MPa for air or inert gases like nitrogen and argon. Flow
rates vary from 0.5-3 Nm3/min/mm2 of nozzle opening area, depending on pressure
and particle size targets.

Q: How small can particles be made through atomization?

A: Gas and water atomization can produce powders down to 5-10 microns. Specialized
techniques like ultrasonic or plasma can generate submicron particles. Smaller sizes
have much lower production rates.

Q: How consistent is the particle size distribution?

A: Well engineered atomization systems can achieve CV of 5-10% on normal particle

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size distribution. Tighter distributions are possible but require extensive process
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Q: How much powder can centrifugal atomization process produce?

A: Centrifugal atomizers are relatively compact and lower cost. Production capacity
ranges from 10-100 kg/h, suitable for small volume specialty alloys.

Q: What determines capital cost of an atomization system?

A: Key factors are alloy being processed, particle size and distribution targets,
production rate, controls, and material of construction. A 500 kg/h gas atomization
MET3DP
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costs around In Themillion.
$1-2 Additive Manufacturing Materials

Q: What safety
MET3DP precautions
Technology Co., LTDare
is aneeded for powder
leading provider atomization?
of additive manufacturing solutions
headquartered in Qingdao, China. Our company specializes in 3D printing equipment and high-
A: Proper personal protective equipment for handling hot metal and atomized powder is
performance metal powders for industrial applications.
critical. Containment of overspray, proper ventilation, monitoring equipment for gases
Inquiry to get best price and customized Solution for your business!
and dusts, and emergency stop circuits help mitigate risks.

Q: What maintenance is required on atomization equipment?

A: Nozzles, spin plates, and collection cyclones wear over time and need replacement.
Related Articles
Hoses, valves, sensors, and pumps must be serviced regularly. Proper start up and
shutdown prevents buildup. Training staff on protocols is vital.

Q: How is powder handling and storage managed after atomization?

A: Powder should be quickly transferred from collectors into sealed containers to limit
exposure and oxidation. Moisture control is critical. Separate room temperature storage
with fire suppression and explosion venting is standard.

Q: What standards apply to atomization system design?

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