The Atomizing Metal Powder Industry

yiyunyingliping October 10, 2023

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Table Of Contents 

1. Share This Post

2. Overview of Atomizing Metal Powder Production

3. A Guide to Atomization Techniques for Metal Powder Production

4. Applications and Uses of Atomized Metal Powders

 5. Specifications and Standards in Atomized Metal Powder Production

6. Equipment Used in Atomization Systems

7. Installation, Operation and Maintenance

8. How to Choose an Atomizing Metal Powder Production Supplier

9. Comparing Atomizing Methods: Pros and Cons

10. Frequently Asked Questions

Overview Of Atomizing Metal Powder

Production
Atomization is a process used to produce metal powders with precise particle sizes
and distributions for use in manufacturing. It involves forcing molten metal through a
nozzle at high pressure into a controlled environment. The metal stream breaks up
into fine droplets that solidify into powder particles.

Atomizing is a key part of powder metallurgy – producing parts through sintering

metal powders rather than machining. The atomization method, nozzle design, and
process parameters determine the morphology, particle size, flowability, apparent
density, and microstructure of the powders produced. These factors have a major
influence on the final properties and performance of metal parts made using the
powders.

Key details about the atomizing metal powder industry:

Produces fine spherical metal powders from micrometers to millimeters in size.

Water, gas, centrifugal, and vacuum atomization are common techniques.
Feedstock is typically steel, aluminum, copper, nickel, cobalt alloys.
Main applications are in automotive parts, cutting tools, bearings, filters,
magnets.
High purity, consistent powder characteristics and particle sizes are required.
High upfront capital costs, significant technical expertise needed.
 The Atomizing Metal Powder Industry 4

A Guide To Atomization Techniques For Metal

Powder Production
There are four primary industrial methods used to atomize molten metal into
powders today. Each has different mechanisms of disintegrating the metal stream
and therefore produces powders with different characteristics.

Table 1: Comparison of Atomization Techniques for Metal Powders

Method How it Works Particle Morphology Cost

Sizes

Water Molten metal stream 5 μm – 2 Irregular, Lowest

Atomization broken up by high mm dentritic
pressure water jets

Gas High velocity inert gas 10 μm – 1 Smooth, Moderate

Atomization used to atomize metal mm spherical

Centrifugal Molten metal poured 20 μm – 5 Irregular, Low

Atomization through spinning disk mm elongated
 Method How it Works Particle Morphology Cost
Sizes

Vacuum Metal vaporized by 10 nm – Spherical, Highest

Atomization plasma/electron beams, 500 μm smooth
condenses in vacuum

Water atomization is the simplest and oldest technology. It produces a wide range of
particle sizes relatively inexpensively. Gas atomization generates very fine, spherical
powders ideal for additive manufacturing using inert gases like nitrogen or argon.

Centrifugal atomization involves rotating discs or drums to disintegrate the molten

metal into elongated particles. It is effective for higher volume production. Vacuum
atomization can produce the finest, purest metal powders using plasma torches or
electron beams in a vacuum chamber.

Applications And Uses Of Atomized Metal

Powders
Atomized powders are used across industries wherever high precision, consistent,
high purity metal powders are required. Some major applications include:

Table 2: Applications of Atomized Metal Powders

Application Uses Key Properties Needed

Powder Metallurgy Automotive parts, cutting Controlled particle size,

tools, bearings spherical morphology

Metal Injection Small intricate parts, medical Ultrafine particle size, free
Molding devices flowing

Additive 3D printing of prototypes, Spherical morphology, good

Manufacturing implants flowability

Surface Coatings Wear/corrosion resistance, Controlled particle

decorative finishes distribution

Magnetic Materials Permanent magnets, High purity, uniform

inductors, sensors composition
 Application Uses Key Properties Needed

Brazing Pastes Joining of metals in Precisely graded mixtures

aerospace, automotive

Automotive parts like gears and connecting rods make up the largest share of
demand for atomized powders today. The ability to produce complex shapes to tight
tolerances makes powder metallurgy attractive for precision components.

Additive manufacturing is one of the fastest growing applications as the technology

improves. Atomized metal powders enable printing of dense, high performance
metal parts. Finer 10-45 micron powders are ideal for printing resolution and accuracy.

Specifications And Standards In Atomized Metal

Powder Production
Atomizing metal powder suppliers must precisely control their process to meet
specifications required by end applications:

Table 3: Typical Specifications for Atomized Metal Powders

Parameter Typical Values Influencing Factors

Particle Size 10 nm – 5 mm Atomization method, molten metal

flowrate, pressure

Particle Shape Irregular, spherical, Atomization method, nozzle design

elongated

Size D10, D50, D90 values Nozzle configuration, metal flowrate

Distribution

Apparent 2 – 5 g/cc Rapid solidification, inert gas flow

Density

Flow Rate Hall flowmeter values Particle shape, surface morphology, size
range

Purity 99.5% to 99.99% Raw material quality, inert gas/water

 Parameter Typical Values Influencing Factors

Oxygen < 100 ppm Water atomization, inert gas levels

Content

International standards help ensure powders consistently meet application needs.

Key standards include:

ISO 4490 – Determination of flow rate through an orifice

MPIF 28 – Determination of apparent density of metal powders
ASTM B214 – Sieve analysis of metal powders
ASTM B809 – Flow rate by Hall flowmeter
ISO 14284 – Steam flow determination

By precisely controlling atomization parameters, suppliers can engineer powders with

customized chemistry, particle sizes, shape, and morphology for their customers’
requirements.

PREPed Metal Powders

Equipment Used In Atomization Systems

Producing atomized metal powders requires specialized equipment to melt,
transport and atomize the metal along with systems to control the process
environment:

Table 4: Key Equipment in an Atomizing Metal Powder Production System

 Equipment Purpose Considerations

Induction melting Heats metal charge to Capacity, temperature

furnace controlled temperature uniformity, atmosphere
control

Tundish with pouring Transfers molten metal to Flow control, temperature

nozzle atomization point maintenance, cleanliness

Atomization nozzles Breaks up molten metal Nozzle design, number of

into droplets/particles nozzles

Gas blowers/water Provides high pressure to Flowrate, pressure,

pumps atomize metal stream temperature control

Powder collection Catches and cools Efficient harvesting,

system atomized particles prevents oxidation

Sieving/classification Separates powder into size Number of fractions,

fractions capacity, ease of operation

Process monitoring Controls key parameters Temperature, pressure, gas

flow, metal flowrate

Proper protective gear and precautions are necessary for safety when working around
high temperature molten metal. Crucibles, launders, nozzles and other parts
contacting the liquid metal must withstand the temperature and corrosion.

Cleanliness is also critical as impurities and oxygen can detrimentally impact powder
quality. All feedstock, equipment, coolants and gases must have very low
contaminant levels.

Installation, Operation And Maintenance

Proper installation, operation and preventative maintenance of atomizing equipment
is essential for safety, consistent production, and costs:

Table 5: Atomizing Metal Powder System Installation, Operation and

Maintenance
 Activity Procedure Frequency

Equipment Follow manufacturer instructions for Prior to startup

Installation assembly, utilities, controls

Safety Checks Test emergency stops, alarms, interlocks, Before each

safety gear batch

Equipment Calibrate sensors, adjust controls to setting Quarterly

Calibration points

Leak Checks Check for leaks in water, gas, vacuum lines Monthly

Nozzle Wear Inspect nozzle throat and face for 100-300 hr

wear/damage

Filter Changes Replace water, gas, dust filter cartridges 500 hr

Equipment Remove powder buildup and oxide scale 1000 hr

Cleaning

Audit Process Data Analyze trends in key parameters Each batch

Preventative Complete checklists for pumps, blowers, 2000 hr

Maintenance drives

Refractory Check furnace lining integrity Annual

Inspection

Training operators on proper startup, shutdown, safety, and troubleshooting

procedures is vital as well. Following recommended maintenance schedules for the
induction furnace, nozzles, pumps, blowers, and other components reduces
unplanned downtime.

Auditing process data regularly is also important to identify any deviations from
optimal settings early. Working closely with equipment suppliers facilitates proper
installation, operation, and maintenance.

How To Choose An Atomizing Metal Powder

Production Supplier
Selecting the right partner is key when purchasing atomized metal powder:
Table 6: How to Choose an Atomizing Metal Powder Supplier

Considerations Details

Technical Capability Experience with different metals, atomization methods,

range of particle sizes produced

Quality Systems ISO certification, established QC testing procedures, lot

traceability, documentation

Customization Flexibility to tailor chemistry, particle size distribution,

Ability morphology to your requirements

R&D Expertise Metallurgy knowledge to develop custom alloys and powder

characteristics

Safety Record Proper safety training for employees, history of safe

operations

Production Sufficient capacity for your volume needs, scalability for

Capacity future growth

Cost Pricing in line with market, ability to reduce costs for large
Competitiveness orders

Customer Service Responsiveness to requests, proactive communication,

technical support

Logistics Ability to store/ship products to prevent contamination

Prioritizing factors like technical expertise, customization capability, and quality

systems helps ensure a supplier can consistently produce powders to your
specifications. Visiting a supplier’s production facility provides helpful insights as well.
Establishing a partnership with effective communication enables collaboration to
continuously improve powder quality and performance.

Comparing Atomizing Methods: Pros And Cons

There are tradeoffs between different atomizing techniques – each has advantages
and limitations important to consider:

Table 7: Comparing Atomizing Metal Powder Production Methods

 Method Advantages Disadvantages

Water Lower capital and operating Less control over size

Atomization costs, larger particle sizes distribution, irregular shapes,
contamination risks

Gas Produces fine spherical High inert gas consumption,

Atomization powders ideal for AM, smaller particle sizes
excellent size control

Centrifugal Good for high volume Less control over size distribution
Atomization production of larger particles and morphology

Vacuum Ultrafine pure powders Very high capital costs, lower

Atomization produced, inert environment production rates

For most powder metallurgy applications, gas atomization provides the best balance
of particle size control, spherical morphology, reasonable throughput and costs.

Water atomization is the simplest and most cost effective especially for coarser
powders above 100 microns. Vacuum systems allow superior control over powder
characteristics but are far more expensive.

The optimum atomization method depends on the metal alloy being processed,
production volumes, final application requirements, and budget constraints. Working
with an experienced supplier will help select the right atomizing technology for your
specific needs.
 PREPed Metal Powders

Frequently Asked Questions

Q: What is the typical price range for purchasing atomized metal powders?

A: Atomized metal powder prices vary widely from around $5-10/lb for common
materials like stainless steel to $50-100/lb for niche alloys. Ultrafine powders below 10
microns for AM can range from $100-1000/lb. Large order quantities above 10 tons
usually qualify for significant volume discounts.

Q: Can alloy chemistry and powder characteristics be customized?

A: Yes, experienced suppliers work closely with customers to tailor powder

composition, particle size distribution, morphology, apparent density and other
properties to meet application requirements through adjusting atomization process
parameters.

Q: How are atomized powders handled and stored to prevent contamination?

A: Atomized powders are highly reactive and can oxidize or absorb moisture easily.
Careful handling in sealed containers under inert gas and climate controlled storage
helps maintain purity. Most suppliers ship powders in vacuum sealed drums with
moisture absorbers.
Q: What safety precautions are required when working with atomized metal
powders?

A: Fine powders are highly flammable and pose explosion risks. Proper protective gear
like masks and gloves should be worn to prevent inhalation or skin exposure during
handling. Powder quantities and dust levels should be minimized and proper
grounding used to avoid static discharge.

Q: What are common defects in atomized powders and how can they be
prevented?

A: Satelliting occurs when smaller particles bond to larger particles during

solidification. This can be reduced by optimizing atomization and cooling parameters.
Contamination from refractories or improper material handling negatively impacts
purity so cleanliness is critical.

Q: How stable are atomized metal powder properties over time?

A: If stored properly in a sealed inert environment, atomized powders maintain their

original properties for many years. However quality should still be verified before use
as improper storage can lead to oxidation or moisture absorption that degrades
powder properties. Shelf life depends on the metal alloy.

Q: What testing is performed to ensure atomized powder quality and

consistency?

A: Suppliers thoroughly test every powder lot using techniques like sieve analysis, Hall
flowmetry, apparent density measurement, microscopy, and laser diffraction to verify
particle size distribution, morphology, flowability and microstructure meet
specifications. Chemical analysis confirms composition and purity.

Q: What are the latest innovations in atomized metal powder production

technology?

A: Nozzle designs that incorporate ultrasonic vibration have been developed to

produce more uniform droplets and finer powders. Manufacturers continue pushing
to economic production of nanoparticles below 100 nm for advanced applications. In-
process monitoring and automated control systems help improve consistency.

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