NAME Ultrasonic metal powder atomization cell
3DLab's ATOLab+ ultrasonic atomizer enables the production of non-reactive and reactive metal powders for the additive manufacturing sector as well as for more conventional sectors. Services include the design and manufacture of ad-hoc experimental casts in all types of Fe, Al, Ni,... based materials in the casting unit and their subsequent transformation into powder, with the possibility of graduating the composition of alloys and microalloys. Another service consists of the manufacture of metal powder from material supplied by the customer in wire, bar or chip format.
FIELDS OF APPLICATION
Design and development of materials
MOST OUTSTANDING EQUIPMENT AND COMPONENTS
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Arku bidezko fusio modulua
The arc melting module allows metal melting on the ultrasonic platform of 1-10 mm diameter bars and 0.8-1.2 mm diameter metal wires for subsequent atomization.
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Induction melting equipment
The induction melting module is designed for melting chips and any other type of geometries in intermediate melting point materials such as aluminum alloys for subsequent atomization. It allows the recycling of these materials to manufacture high quality metal powder.
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Powder quality control facilities
The set of powder quality controls performed at Azterlan consists of the measurement of the fluidity, powder moisture, composition analysis by ICP-OES. Its size distribution can also be evaluated by scanning electron microscope inspection and subsequent analysis of the captured images.
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Ultrasonic automatic sieving system
The system allows for screening of the manufactured powder in the following sizes: 20, 45, 63, 100 and 120 µm. The powder that has passed through the sieve retains its protective atmosphere.
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Ultrasonic metal atomization system with generators of 35 and 52 kHz
The ultrasonic module can be either 35 or 52 kHz. The higher the frequency of the ultrasonic sonotrode the smaller the size of the manufactured dust particles, the range being 25-55 µm for 52 kHz and 25-70 µm for 35 kHz.
SERVICES OFFERED BY THE ASSET
Design and development of powders adjusted to manufacturing process/component
To design the most adequate alloying elements for metallic powder to be manufactured in the Azterlan facilities; the product manufacturing needs and the influence of process variables on the final component will be analyszed. Thermodynamic and thermokinetic simulations will be applied.
Manufacturing ad-hoc metallic powders, especially in Fe, Al, Ni, and other alloy based.
Bezeroak metalak eraldatzeko definitutako konposizio kimikoaren urtzea eta galdaketa Azterlan-eko unitatean: Fe, Al, Cu, Ni, HEA, etab. baseas. Barra metalikoen ekoizpena gero ultrasoinu bidez atomizatzeko, 50g-tik 5kg-rarte.
Manufacturing of “master alloys” in powder format
“Master alloys” manufacturing in powder format: this service will allow the manufacturing of doped powder with the selected elements which could be used as “master alloys” for mixing with commercial powders to obtain tuned chemical composition ad-hoc powders varying depending on the mixture ratio.
Metal atomization from wires or rods
Powder batches from 50 g up to 5 kg manufactured from metal provided by the customer in reactive and nonreactive materials: wire or rod. Narrow size distribution, high particles sphericity and the absence of inner porosity are assured.
Recycling of shavings and post-production rests
Ultrasonic atomization of alloys in shavings and/or rests of post-production format in order to obtain recycled powder: aluminium shaving, rests of cutting and machining materials, etc.
ENTITY MANAGING THE ASSET
Contact person:
Ana Isabel Fernández
afernandez@azterlan.es