WO1993013897A1 - Procede de production d'une pulverisation de poudre de metal - Google Patents
Procede de production d'une pulverisation de poudre de metal Download PDFInfo
- Publication number
- WO1993013897A1 WO1993013897A1 PCT/GB1993/000105 GB9300105W WO9313897A1 WO 1993013897 A1 WO1993013897 A1 WO 1993013897A1 GB 9300105 W GB9300105 W GB 9300105W WO 9313897 A1 WO9313897 A1 WO 9313897A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- metal
- filaments
- metal alloy
- molten
- mesh
- Prior art date
Links
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 109
- 239000002184 metal Substances 0.000 title claims abstract description 109
- 239000000843 powder Substances 0.000 title claims abstract description 11
- 239000007921 spray Substances 0.000 title claims description 31
- 238000000034 method Methods 0.000 title claims description 29
- 239000000758 substrate Substances 0.000 claims abstract description 25
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 28
- 238000001816 cooling Methods 0.000 claims description 16
- 239000007789 gas Substances 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 11
- 239000002893 slag Substances 0.000 claims description 11
- 238000007667 floating Methods 0.000 claims description 5
- 239000000112 cooling gas Substances 0.000 claims description 4
- 230000004907 flux Effects 0.000 claims description 4
- 150000003839 salts Chemical class 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims 1
- 238000007789 sealing Methods 0.000 claims 1
- 238000000576 coating method Methods 0.000 abstract description 3
- 239000011248 coating agent Substances 0.000 abstract 2
- 238000005507 spraying Methods 0.000 abstract 1
- 238000009718 spray deposition Methods 0.000 description 15
- 229910000831 Steel Inorganic materials 0.000 description 13
- 239000010959 steel Substances 0.000 description 13
- 150000002739 metals Chemical class 0.000 description 12
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 9
- 230000008901 benefit Effects 0.000 description 9
- 229910052786 argon Inorganic materials 0.000 description 5
- 239000012535 impurity Substances 0.000 description 5
- 239000007788 liquid Substances 0.000 description 5
- 229910001338 liquidmetal Inorganic materials 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 4
- 239000000956 alloy Substances 0.000 description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 239000002131 composite material Substances 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 238000004663 powder metallurgy Methods 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000005484 gravity Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 230000005855 radiation Effects 0.000 description 3
- 239000011819 refractory material Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 238000009736 wetting Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000009689 gas atomisation Methods 0.000 description 2
- 230000002706 hydrostatic effect Effects 0.000 description 2
- 239000002923 metal particle Substances 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 229910018516 Al—O Inorganic materials 0.000 description 1
- 229910000599 Cr alloy Inorganic materials 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 239000012634 fragment Substances 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 210000003041 ligament Anatomy 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000003362 replicative effect Effects 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 238000005204 segregation Methods 0.000 description 1
- 229910052566 spinel group Inorganic materials 0.000 description 1
- -1 steels Chemical class 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
- B01J2/02—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops
- B01J2/04—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by dividing the liquid material into drops, e.g. by spraying, and solidifying the drops in a gaseous medium
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/123—Spraying molten metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F2009/0804—Dispersion in or on liquid, other than with sieves
- B22F2009/0808—Mechanical dispersion of melt, e.g. by sieves
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
- B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
- B22F2009/0816—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying by casting with pressure or pulsating pressure on the metal bath
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
Definitions
- This invention is concerned with the processing of metals and alloys.
- the processing of metals and alloys into useful products often involves first producing the metal in particulate form.
- the obvious example is the use of powder metallurgy but a more recent and potentially more far reaching processing route is that of spray forming.
- the invention relates to the production of particulate metals and it is the latter processing route that will be described in detail although the invention can clearly be used to produce excellent powder metallurgy products.
- Metals, alloys and composites are frequently processed into required forms by spray forming.
- the molten metal is usually atomised by means of high pressure gas or by centrifugal means to form a spray of molten or semi- molten droplets that is directed towards a cool substrate.
- the droplets splat on the substrate or on the cooler prior solidified deposit and solidify to produce a spray formed product.
- the spray formed product can be a plate or strip, a tube, a hollow billet or a solid billet as well as several other forms. Laminates, coatings and composites can readily be made by spray forming.
- a further more difficult problem concerns the variations in size, velocity and temperature of the atomised particles.
- Gas atomising is the most popular type of atomising for spray forming but it invariably produces a very wide range of particle sizes leading to a wide range of particle temperatures. In general terms the smallest particles are solid on reaching the substrate, intermediate ones are partially liquid and the large ones are fully liquid.
- typical atomised sprays have a much higher spray density at the centre of the spray cone and a far lower one at the fringe of the spray cone. If a substrate moves through a spray cone it will first receive a light deposit of particles from the front of the fringe followed by a heavy deposit from the centre of the cone and then a light final deposit from the rear of the fringe.
- a container having a base formed from either a relatively coarse steel mesh or steel plate pierced with a multitude of holes or apertures is situated at the top of a tower. Molten lead is poured through the mesh or plate forming lead droplets which cool as they descend within the tower to form lead shot often 1 or 2mm in diameter. It is not possible for this method to be directly applied to the production of metal particles of engineering metals and alloys including iron, aluminium, copper alloys and high temperature metals for spray forming or powder metallurgy because -
- the sizes of particles required are of the order of 200 ⁇ m or less and this would lead to major manufacturing problems in producing an appropriate plate in addition to subsequent operating difficulties, and (ii) the engineering metals would react with the steel plates or mesh.
- Materials that would be suitable for meshes or plates for the engineering materials are stable high temperature refractories such as Al-O.,, Si0_, ZrO-, SiC, mixed oxides, certain spinels and for particular metals, carbon.
- a pierced plate of such refractory materials with a multitude of 200 ⁇ m holes would have to be comparatively thick to support the weight of molten metal above it with the result that the holes would have a very large length diameter ratio.
- a process for producing a particulate spray of metal or metal alloy comprising enclosing the metal or metal alloy in a molten state in a vessel at least part of the bottom of which is constituted by first and second layers of spaced refractory filaments which are under tension, the spaced filaments in the first layer being in contact with and extending transversely with respect to the spaced filaments in the second layer so that the two layers jointly define a mesh with a multiplicity of small apertures, and subjecting the metal or metal alloy above said layers of filaments to pressure pulsating between a lower value insufficient to force the molten metal or metal alloy through the apertures against the forces of surface tension and a higher value sufficient to force the molten metal or metal alloy through the apertures, thereby to produce a particulate of spray of metal or metal alloy.
- Such a process can provide a solution to the above-mentioned difficulties because:- (i) it can provide a high strength thin mesh in which the distance between apertures can be decreased or increased respectively by using wider or narrower tapes in particular positions, thus providing a means of controlling the distribution of the droplets over the area of the mesh; (ii) it enables single crystal fibres or tapes to be used which greatly increases the creep strength of the fibre or tape at high temperature thus improving the high temperature performance of the mesh; (iii) it can provide a method of cleaning the apertures to avoid blockage; and (iv) it provides a means of breaking the issuing metal into droplets of controllable size.
- the spray or shower of droplets may be allowed to fall through a chamber in which they cool to form a powder for use in powder metallurgy, or a substrate or collector, which may be moving or stationary, may be disposed near the bottom of a spray chamber so that the droplets hit the substrate or collector and solidify to produce a spray formed product replicating the contour of the substrate or collector.
- a substrate or collector which may be moving or stationary, may be disposed near the bottom of a spray chamber so that the droplets hit the substrate or collector and solidify to produce a spray formed product replicating the contour of the substrate or collector.
- One or more additional layers of refractory filaments may be incorporated in the mesh.
- the invention also provides apparatus for producing a particulate spray of metal or metal alloy, comprising means for supplying the metal or metal alloy in a molten state into a chamber, the bottom of which is constituted by first and second layers of spaced refractory filaments which are under tension, the spaced filaments in the first layer being in contact with and extending transversely with respect to the spaced filaments in the second layer so that the two layers jointly define a mesh with a multiplicity of small apertures, and means for subjecting the molten metal or metal alloy in the chamber to a pressure pulsating between a lower value insufficient to force the molten metal or metal alloy through- the apertures against the forces of surface tension and a higher value sufficient to force the molten metal or metal alloy through the apertures.
- the invention also includes the products produced by the process.
- the filaments of refractory may be of various cross-sections.
- the cheapest and most readily available are of circular cross-section. While in some circumstances single filaments can be used for the construction of a suitable mesh they do not lend themselves to achieving adjustability of the aperture size or aperture spacing. More suitable shapes are of oval cross-section or preferably of rectangular cross- section.
- a number of single circular cross-section filaments may be grouped with their axes parallel to each other so as to form a composite filament having a cross-section closely approximating to an oval, rectangular or other desired section. It is therefore to be understood that the term filament used herein includes such a composite filament.
- the filaments are of rectangular section i.e. they are tapes used with the long dimensions of their cross-section in the plane of the mesh, but it will be understood that this does not preclude the use of other cross-sections for the same purpose.
- the tapes should be composed of an inert high temperature high strength refractory that will not react with or be dissolved by the molten metal.
- High strength fibres are particularly useful such as 1_0 ⁇ or Si0_ because they can be drawn as circular section fibres or bundles of fibres and then flattened to produce tapes. Filaments and tapes of Al ⁇ O-,, SiC and carbon can be used provided they meet the criteria mentioned above.
- a particularly useful form of fibre is that in single crystal form. Such single crystal fibres can be grown either in circular or rectangular cross- section and have the special advantage of a high creep strength. Notable amongst these materials are A1_0-. and certain mixed oxides such as Mg 0 Al-O-,. The latter has a particularly high creep strength at high temperature. It is an advantage but not a necessity for the refractory to be non-wetting to the molten metal because this enables greater control of the metal droplet size to be exercised.
- the tapes are held in place under tension in order to support the weight of liquid metal above.
- the overall shape of the assembly of tapes forming the mesh could be rectangular.
- the shorter tapes when under tension would support the major part of the weight of the molten metal above and the longitudinal ones would serve mainly to determine the aperture size.
- the tapes extending in one direction can be moved in that direction, in the plane of the mesh, in relation to the tapes in the other direction. This can be done with good effect during the operation of the process.
- the tapes in the direction of their length and the reciprocation can be continuous or intermittent and need only be of the order of a few aperture spacings. Small fragments of oxide or other impurities in the molten metal that have blocked the apertures will quickly be removed enabling the droplet forming process to proceed without interruption.
- the molten metal is subjected to pulsating pressure. This can be done in three main ways and it much depends on the molten metal and particular circumstances as to which is used. The three practical alternatives being the use of a solid substantially horizontal plate vibrating vertically in the molten metal or in a layer of liquid slag, flux or fused salts floating on the molten metal or a vibrator in the gas above the liquid metal.
- Vibration of a plate within the molten metal is easiest when lower melting point metals such as lead and zinc are being atomised because higher melting point metal plates, for example steel plates, suitably coated if necessary to avoid solution in the molten metal, can be used.
- a suitable arrangement is a vibrating metal plate vibrating in a vertical mode immersed in a layer of liquid slag, flux or fused salt of lower density than the molten metal and which is floating on top of the molten metal.
- slags, fluxes or molten salts will have a melting point substantially below that of the molten metal, they are chosen to be insoluble in the metal and have a much lower thermal conductivity.
- a metal plate to be immersed in and operated in the slag layer at a lower temperature than the molten metal .
- a vibrating plate made of steel or a Ni Cr alloy would be adequate because temperatures in the slag can be maintained at a substantially lower level than those in the molten metal.
- the vibrating plate will be insoluble in the molten slag and will therefore not be attacked by it.
- the third alternative of using a pulsating gas is convenient for relatively low frequency vibration up to say 50Hz but at higher frequencies the compressibility of the gas makes it less effective. In general terms reducing the frequency . of vibration lowers the throughput of droplets and increases the likelihood of resonance of the mass of liquid metal lying on the mesh.
- very high frequency usually means low amplitude leading to a continuous uncontrollable stream of liquid metal emerging from the mesh. Cavitation may also occur at high frequencies.
- the metal droplets On issue from the mesh the metal droplets will rapidly become spherical, and accelerate downwards due to gravity and the vertical distances between the droplets will increase. There may be a very small amount of sideways random motion and a few of the droplets may collide to form larger drops, but generally the drops will fall vertically through the chamber to cool to form powder, or, as the case may be, will hit a substrate on which they will cool and solidify.
- the droplets cool during their fall by radiation to the cool walls of the chamber and by convection with the air or gas in the chamber. Gas may be cooled and circulated through the chamber if necessary but care must be taken not to deflect the droplets by a high gas velocity otherwise the spray pattern will be disturbed.
- the substrate may be a rotating metal drum or a moving belt in which case the overall shape of the mesh may be rectangular with the short side extending in the direction of travel.
- most of the cooling would be caused by the cool drum or belt and typical thicknesses of strip would be from 2mm to 5mm.
- the mesh may be in the shape of a circle or square for square section billets.
- the prior spray-formed part of the billet cools naturally or is subjected to cooling to enable later impinging droplets to solidify.
- the pattern of droplets follows closely the pattern of the mesh. There is a sharp cut-off at the edges and most of the droplets are of similar size and have similar final velocities. In this respect it differs markedly from gas atomisation where the cut-off is not sharp and where size, temperature and velocity of the atomised particles vary widely.
- Figure 1 shows a longitudinal cross-section of an apparatus making an aluminium alloy strip by the process of the invention.
- FIG 2 is a fragmentary sectional view on the line 2-2 of Figure 1, and Figure 3 illustrates a second form of apparatus according to the invention.
- an oblong refractory lined vessel 10 is positioned such that when viewed from above its longer dimension is perpendicular to the direction of travel of a substrate 11 spaced below the vessel and its shorter dimension is parallel to the direction of travel of the substrate.
- the rectangular vessel has a fine mesh 12 which constitutes most of the bottom surface of the vessel.
- the mesh is composed of an upper layer of alumina tapes 13 arranged in the long dimension of the rectangular vessel resting on a lower layer of alumina tapes 14 extending in the direction of the shorter dimension of the rectangular vessel.
- the two layers of tapes are arranged such that they are at right angles to one another and the tapes in each layer are spaced slightly apart to give a mesh consisting of an array of square apertures.
- the tapes in this instance are 500 ⁇ m in width and 300 ⁇ m in thickness spaced 200 ⁇ m apart and are composed of high strength non-wetting alumina.
- Each of the two layers of tapes is clamped tightly in its own rigid rectangular frame 15 and the tapes are held firmly in tension by the two frames.
- Molten aluminium alloy 18 is fed to the rectangular vessel 10 from a tundish 19 the top surface of the molten metal in the tundish being at a higher level than that in the rectangular vessel to form a metalostatic head of approximately 100mm above the mesh. Because the mesh is very fine, consisting of an array of rectangular apertures 200 ⁇ m square, the molten metal in the vessel will not flow through the apertures of the mesh because of the resistance of the surface tension forces at the interface of the molten aluminium and the gas in a chamber 20 which is disposed below the mesh 12. Chamber 20 has an inlet 21 and an outlet 22 for a flow of cooling gas. A moving metal belt 23 forming the substrate 11 extends through slots 24 in the wall of the chamber.
- the vessel 10 has a refractory top 10a to which is connected a vertical steel cylinder 25 provided with a steel piston 26, and the space above the metal communicates with the lower end of the cylinder through passages 27 in the top 10a of the vessel.
- the space above the metal and in the cylinder is filled with argon.
- the tundish 19 provides a reservoir 18 of molten metal and communicates with the metal in the vessel through a feeder passage 29.
- this arrangement gives a small downward pressure on the molten metal on the mesh equal to the etaiostatic head arising from the vertical distance between the top surface of the metal in the tundish 19 and the mesh, which in this case is 100mm.
- the molten metal does not flow through the apertures because the metaiostatic head is insufficient to overcome the surface tension forces preventing the issue of molten aluminium alloy from the apertures between the non-wetting alumina tapes.
- the piston 26 is reciprocated rapidly in a vertical direction so applying an oscillating pressure to the metal above the mesh.
- the pressure also causes a small oscillating movement in the metal in the feeder 29 and in the tundish 19 but the inertia of the molten metal in the feeding system causes attenuation such that most of the pressure increase at the stroke of the piston causes molten metal to flow through the apertures of the mesh against the resistance caused by surface tension.
- the piston 26 is oscillated in simple harmonic median at a frequency of 20Hz over a distance of 50mm.
- a single droplet 30, Figure 2 is forced through each aperture of the mesh against the surface tension forces.
- the droplets 30 accelerate vertically downwards under gravity through the bottom chamber 20 which is filled with argon, becoming more widely spaced vertically as they descend until they hit the moving cool metal substrate in the form of the moving metal belt 23.
- the droplets hit the surface of the substrate and coalesce to form a spray deposit 32.
- This deposit can be subsequently removed from the substrate and rolled or treated in just the same way as a conventional spray formed deposit.
- the droplets may adhere to the substrate to form a coated product.
- the level of the molten metal in the tundish is maintained fairly constant between 80mm and 120mm in depth by topping up with further molten metal as it is used in the process.
- the process of the invention has many advantages over conventional spray forming, such as a higher utilisation of the metal droplets, comparatively uniform droplet size, temperature and speed, the process is less favourable in the respect that there is little convective cooling from the gas in the chamber 20 in Figure 1.
- Some cooling occurs by radiation to the chamber walls and these may be made of water-cooling metal and the chamber may be made tall in order to increase such cooling.
- much of the cooling will occur by conduction from the substrate and from the prior solidified deposit. For this reason the process of the invention is well suited to making thin strip from 1mm to 3mm in thickness.
- tubular products can be made by deposition on a rotating horizontal mandrel or on a rotating collector to which it bonds tightly. In this case much of the cooling occurs by radiation from the prior solidified deposit which is returned to the descending spray at each revolution.
- rotating and static billets can be made as with conventional spray forming except that adequate provision must be made for cooling the deposit to ensure that incremental solidification takes place (SINGER A.R.E. & EVANS R.W. Incremental Solidification and Forming. Metals Technology. February 1983. Vol. 10. pp. 61-881 and to ensure that a deep pool of molten metal is avoided.
- the chamber 20 in Figure 1 is filled with the inert gas argon and the gas is practically static.
- a small amount of -argon is fed in at port 21 under a very low pressure and exits at port 22 to ensure that no air enters the chamber.
- a different arrangement is employed for transmitting a pulsating pressure to the molten steel in the vessel 10.
- a 25mm layer of fused slag 36 based on CaO floats on the liquid steel 37 in the vessel, the depth of steel being approximately 50mm, and a metal plate 38 is immersed in the slag.
- the plate 38 has a stem 39 which is attached to a transducer 40.
- the transducer causes the plate 38 to vibrate in a vertical mode at a frequency of 100Hz.
- the pulsing pressure in the molten slag 36 is transmitted directly to the molten steel 37 which in turn transmits pressure to the molten steel above the apertures forcing it through to form droplets as described previously.
- the process can be used for making powder as well as for spray forming.
- powder When powder is being made it is essential to provide sufficient cooling and such a height of tower that the greater part of each droplet is frozen by the time it falls to the bottom of the chamber. No substrate will be needed although a conveyor system will be required to deliver the solidified powder from the equipment.
- higher upward velocities of cooling gas are possible because the preservation of the pattern of the droplets is not important.
- Most powder, but not shot is required in the range of 50 to 100 ⁇ m which means closer spacing of the tapes than would generally be required by spray forming but there is a corresponding advantage that the height of the cooling tower would be lower because of the more rapid cooling of the smaller particles owing to their having a higher surface area-mass ratio.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
Abstract
Appareil de métallisation au pistolet permettant de former sur un substrat du métal sous forme de poudre ou de revêtement, comprenant un tamis (12) constitué de deux couches (13, 14) s'étendant mutuellement dans le sens transversal composées de filaments réfractaires espacés soumis à un effort de traction. Les filaments de la couche supérieure sont en contact avec les filaments de la couche inférieure. Le tamis constitue la paroi de fond d'une cuve dans laquelle se trouve le métal fondu. Le métal fondu situé dans la cuve est soumis à une pression de pulsation comprise entre des valeurs supérieures et inférieures qui se situent respectivement au-dessus et au-dessous de la valeur à laquelle la pression est suffisante pour surmonter les forces de tension superficielle s'opposant à l'écoulement du métal à traver les ouvertures du tamis. Un piston (26) coulissant dans un cylindre vertical (25) est soumis à un mouvement de va-et-vient afin que le gaz situé au-dessus du métal fondu contenu dans la cuve (10) applique la pression de pulsation sur la surface du métal. Les gouttelettes (30) de métal fondu tombent dans un espace fermé qu'elles traversent pour se déposer sur un substrat froid (23) en formant un revêtement sur ce dernier.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9200936.4 | 1992-01-16 | ||
GB929200936A GB9200936D0 (en) | 1992-01-16 | 1992-01-16 | Improvements in the processing of metals and alloys |
Publications (1)
Publication Number | Publication Date |
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WO1993013897A1 true WO1993013897A1 (fr) | 1993-07-22 |
Family
ID=10708724
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/GB1993/000105 WO1993013897A1 (fr) | 1992-01-16 | 1993-01-18 | Procede de production d'une pulverisation de poudre de metal |
Country Status (2)
Country | Link |
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GB (1) | GB9200936D0 (fr) |
WO (1) | WO1993013897A1 (fr) |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5778964A (en) * | 1995-06-13 | 1998-07-14 | Nihon Almit Co., Ltd. | Solid spherical body manufacturing apparatus |
RU2137574C1 (ru) * | 1998-07-14 | 1999-09-20 | Закрытое акционерное общество "Научно-производственное предприятие ФАН" | Устройство для получения металлических гранул |
US7422619B2 (en) * | 2000-11-17 | 2008-09-09 | Accurus Scientific Co., Ltd. | Process of fabricating metal spheres |
EP3192586A1 (fr) * | 2016-01-18 | 2017-07-19 | Palo Alto Research Center, Incorporated | Système et procédé de revêtement d'un substrat |
US10434703B2 (en) | 2016-01-20 | 2019-10-08 | Palo Alto Research Center Incorporated | Additive deposition system and method |
RU2707009C1 (ru) * | 2019-05-27 | 2019-11-21 | Константин Николаевич Рязанцов | Способ литья крупной дроби |
US10493483B2 (en) | 2017-07-17 | 2019-12-03 | Palo Alto Research Center Incorporated | Central fed roller for filament extension atomizer |
US10500784B2 (en) | 2016-01-20 | 2019-12-10 | Palo Alto Research Center Incorporated | Additive deposition system and method |
US10919215B2 (en) | 2017-08-22 | 2021-02-16 | Palo Alto Research Center Incorporated | Electrostatic polymer aerosol deposition and fusing of solid particles for three-dimensional printing |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN109434123B (zh) * | 2018-10-26 | 2022-03-22 | 锡矿山闪星锑业有限责任公司 | 一种制备锑珠的装置及方法 |
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US2436211A (en) * | 1945-12-17 | 1948-02-17 | Hart John | Apparatus for producing drop shot |
GB693892A (en) * | 1948-07-23 | 1953-07-08 | Olin Ind Inc | Improvements in or relating to manufacture of shot |
GB813146A (en) * | 1955-12-16 | 1959-05-13 | Universal Oil Prod Co | Improvements in or relating to forming spherical particles |
EP0100467A1 (fr) * | 1982-07-13 | 1984-02-15 | RIV-SKF OFFICINE DI VILLAR PEROSA S.p.A | Procédé de fabrication de billes en acier, en particulier des billes pour paliers à roulement |
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- 1992-01-16 GB GB929200936A patent/GB9200936D0/en active Pending
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Patent Citations (4)
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US2436211A (en) * | 1945-12-17 | 1948-02-17 | Hart John | Apparatus for producing drop shot |
GB693892A (en) * | 1948-07-23 | 1953-07-08 | Olin Ind Inc | Improvements in or relating to manufacture of shot |
GB813146A (en) * | 1955-12-16 | 1959-05-13 | Universal Oil Prod Co | Improvements in or relating to forming spherical particles |
EP0100467A1 (fr) * | 1982-07-13 | 1984-02-15 | RIV-SKF OFFICINE DI VILLAR PEROSA S.p.A | Procédé de fabrication de billes en acier, en particulier des billes pour paliers à roulement |
Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5778964A (en) * | 1995-06-13 | 1998-07-14 | Nihon Almit Co., Ltd. | Solid spherical body manufacturing apparatus |
EP0776726A4 (fr) * | 1995-06-13 | 1999-01-27 | Nihon Almit Co Ltd | Dispositif de fabrication de spheres pleines |
RU2137574C1 (ru) * | 1998-07-14 | 1999-09-20 | Закрытое акционерное общество "Научно-производственное предприятие ФАН" | Устройство для получения металлических гранул |
US7422619B2 (en) * | 2000-11-17 | 2008-09-09 | Accurus Scientific Co., Ltd. | Process of fabricating metal spheres |
US7588622B2 (en) | 2000-11-17 | 2009-09-15 | Henkel Of America, Inc. | Process of fabricating metal spheres |
US9993839B2 (en) | 2016-01-18 | 2018-06-12 | Palo Alto Research Center Incorporated | System and method for coating a substrate |
EP3192586A1 (fr) * | 2016-01-18 | 2017-07-19 | Palo Alto Research Center, Incorporated | Système et procédé de revêtement d'un substrat |
US10112213B2 (en) | 2016-01-18 | 2018-10-30 | Palo Alto Research Center Incorporated | System and method for coating a substrate |
US10434703B2 (en) | 2016-01-20 | 2019-10-08 | Palo Alto Research Center Incorporated | Additive deposition system and method |
US10500784B2 (en) | 2016-01-20 | 2019-12-10 | Palo Alto Research Center Incorporated | Additive deposition system and method |
US10493483B2 (en) | 2017-07-17 | 2019-12-03 | Palo Alto Research Center Incorporated | Central fed roller for filament extension atomizer |
US10919215B2 (en) | 2017-08-22 | 2021-02-16 | Palo Alto Research Center Incorporated | Electrostatic polymer aerosol deposition and fusing of solid particles for three-dimensional printing |
US11413813B2 (en) | 2017-08-22 | 2022-08-16 | Palo Alto Research Center Incorporated | Electrostatic polymer aerosol deposition and fusing of solid particles for three-dimensional printing |
RU2707009C1 (ru) * | 2019-05-27 | 2019-11-21 | Константин Николаевич Рязанцов | Способ литья крупной дроби |
Also Published As
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---|---|
GB9200936D0 (en) | 1992-03-11 |
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