Ultrasonic Assisted Metal Powder Achieves Quality Improvement
Ultrasonic atomization powder technology
1. Technical principles
Ultrasonic atomization powder technology can be divided into contact atomization and non-contact atomization. With the help of high-frequency sound wave vibration energy, the metal liquid flow is accurately broken and dispersed into fine mist like tiny droplets, and then solidified into powder in a specific cooling environment. The contact atomization currently used is suitable for metal materials with low melting points (≤ 1000 ℃), such as magnesium, aluminum, tin, silver, indium, lead, etc.
2. Equipment structure
The core modules include metal melting furnace, atomization tank, ultrasonic metal atomization treatment system, inert gas generator, etc; By adjusting the flow rate of the liquid and the power of the ultrasonic waves, the powder particle size and yield can be controlled.
3. Technological breakthroughs
FUNSONIC has developed ultrasonic metal atomization technology by combining ultrasonic applications with traditional metal powder production methods. Through automated production equipment, the goal of mass production of low melting point metal powder materials can be achieved, which can effectively control the uniformity and particle size of metal powder.
Ultrasonic assisted metal powder processing technology
1. Dispersion and mixing optimization
By utilizing high-frequency ultrasonic vibration and cavitation effect, the metal solution dropped on the ultrasonic tool head is dispersed, promoting the solution to form atomized particles that are uniformly dispersed, and the gas in the liquid is released without adhesion, achieving consistency between powder dispersion and formed particles.
2. Particle size control and screening
The atomized solidified particles can be screened with high precision using an ultrasonic vibrating screen device to obtain uniformly sized powders.
Technological breakthroughs and application prospects
1. 3D printing and additive manufacturing
Ultrasonic atomization powder technology is used to prepare ultrafine metal powders with high sphericity and low oxygen content. It can meet the strict requirements of powder flowability and density in additive manufacturing, such as application in precision manufacturing fields such as special coatings and medical devices.
2. Powder metallurgy
Iron based and copper based alloy powders produced through ultrasonic atomization technology can be directly used in powder metallurgy processes to manufacture high-strength gears, wear-resistant bearings, and other components, optimizing the porosity and material uniformity of traditional processes.
3. Electronics and Semiconductors
High purity copper powder, silver powder and other conductive materials can achieve nanoscale particle size control through ultrasonic milling technology, which is applied in integrated circuit conductive paste, electronic packaging and other scenarios to improve device conductivity and reliability.
4. Energy and Chemical Industry
Battery materials: Nano scale nickel and cobalt powders prepared with ultrasonic assistance are used as positive electrode materials for lithium batteries to improve energy density and cycling stability;
Catalyst: Ultra fine metal powders such as iron and cobalt are used as active components of industrial catalysts to accelerate chemical reaction efficiency.
5. Aerospace and Military Industry
Non contact ultrasonic powder production technology can produce high melting point alloy (such as tungsten carbide, titanium alloy) powder, which is used for spray repair or direct molding of high-temperature components such as rocket nozzles and aircraft engine blades.
6. Biomedical
Medical titanium alloy and magnesium alloy powders are prepared using ultrasonic atomization technology for bone implants or 3D printed customized prostheses, with both biocompatibility and mechanical properties.
Development trend
At present, ultrasonic powder production technology still faces challenges such as high research and development costs for high melting point atomization equipment, deep development in industrial application fields, and low finished product output. In the future, it is necessary to further strengthen cooperation between advanced manufacturing enterprises and research institutes, form consensus and project planning, and make breakthroughs in key technologies such as ultrasonic metal atomization technology for preparing different metal powder materials.
