Overview
Plasma atomisation is a highly advanced process for producing metal powders with exceptional quality and consistency. This technique utilizes a high-energy plasma torch to melt and atomize metal feedstock into fine spherical particles, making it crucial in industries like aerospace, medical, and additive manufacturing. The resulting powders are prized for their uniform size, shape, and high purity, essential for applications requiring high performance and reliability.
What is Plasma Atomisation?
Plasma atomisation involves using a plasma torch to melt a metal feedstock, which is then subjected to a high-velocity gas stream that disperses the molten metal into fine droplets. These droplets solidify into spherical particles as they cool. The process is highly controlled and can produce powders with specific particle size distributions and characteristics.
The Importance of Plasma Atomisation
Why is plasma atomisation so important? It’s all about precision and quality. Traditional atomisation techniques often struggle with consistency and purity, which can lead to variations in the final product. Plasma atomisation, on the other hand, offers unparalleled control over the process, resulting in powders that are uniform, pure, and perfect for high-tech applications.
Types, Composition, Properties, and Characteristics of Plasma Atomisation Powders
Here, we delve into the specifics of various metal powders produced through plasma atomisation, focusing on their types, composition, properties, and characteristics.
Types of Metal Powders
| Metal Powder | Composition | Properties | Characteristics |
|---|---|---|---|
| Titanium (Ti) | 99.9% Ti | High strength-to-weight ratio, corrosion-resistant | Spherical shape, high purity |
| Inconel (Ni-Cr alloy) | 60% Ni, 23% Cr, others | High-temperature strength, oxidation-resistant | Fine, spherical particles |
| Stainless Steel (316L) | 17% Cr, 12% Ni, 2.5% Mo | Corrosion-resistant, good mechanical properties | Uniform particle size, spherical |
| Aluminum (Al) | 99.7% Al | Lightweight, good conductivity | Fine, spherical particles |
| Copper (Cu) | 99.9% Cu | Excellent conductivity, malleable | Uniform shape, high purity |
| Cobalt-Chromium (Co-Cr) | 55% Co, 30% Cr, others | Wear-resistant, biocompatible | High sphericity, fine particle size |
| Tantalum (Ta) | 99.9% Ta | High melting point, corrosion-resistant | Spherical particles, high purity |
| Nickel (Ni) | 99.9% Ni | Corrosion-resistant, good mechanical properties | Uniform, spherical particles |
| Magnesium (Mg) | 99.8% Mg | Lightweight, good machinability | Fine particles, high purity |
| Zirconium (Zr) | 99.9% Zr | High corrosion resistance, biocompatible | Spherical, fine particles |
Applications of Plasma Atomisation Powders
| Application | Metal Powder Used | Purpose |
|---|---|---|
| Aerospace | Titanium, Inconel, Aluminum | High strength, lightweight components |
| Medical Devices | Cobalt-Chromium, Titanium | Biocompatibility, strength |
| Additive Manufacturing | Stainless Steel, Titanium | Consistent, high-quality 3D printing |
| Electronics | Copper, Nickel | Excellent conductivity |
| Automotive | Aluminum, Magnesium | Lightweight, durable parts |
| Tooling and Dies | Inconel, Stainless Steel | High wear resistance |
| Jewelry | Gold, Silver, Platinum | High purity, aesthetic appeal |
| Energy Sector | Zirconium, Tantalum | High corrosion resistance |
| Consumer Goods | Stainless Steel, Aluminum | Durability, aesthetic properties |
Specifications, Sizes, Grades, Standards of Plasma Atomisation Powders
| Metal Powder | Size Range (µm) | Grades Available | Standards |
|---|---|---|---|
| Titanium (Ti) | 15-45, 45-90 | CP1, CP2, CP3, CP4 | ASTM F67, F136 |
| Inconel (Ni-Cr alloy) | 15-53, 53-150 | IN718, IN625 | AMS 5662, AMS 5663 |
| Stainless Steel (316L) | 15-45, 45-105 | 316L, 304L, 17-4PH | ASTM A276, A240 |
| Aluminum (Al) | 20-63, 63-150 | 6061, 7075 | ASTM B209, B221 |
| Copper (Cu) | 15-45, 45-90 | OFC, ETP | ASTM B170, B187 |
| Cobalt-Chromium (Co-Cr) | 10-45, 45-90 | CoCrMo, CoCrW | ASTM F75, F1537 |
| Tantalum (Ta) | 15-45, 45-150 | R05200, R05400 | ASTM B521, B708 |
| Nickel (Ni) | 15-53, 53-150 | 200, 201 | ASTM B160, B162 |
| Magnesium (Mg) | 15-45, 45-105 | AZ31, AZ61 | ASTM B107, B90 |
| Zirconium (Zr) | 10-45, 45-105 | 702, 705 | ASTM B551, B493 |
Suppliers and Pricing Details
| Supplier | Metal Powder | Price Range (per kg) | Notes |
|---|---|---|---|
| AP&C | Titanium, Inconel | $200 – $300 | High-quality, aerospace-grade |
| Sandvik | Stainless Steel, Nickel | $150 – $250 | Consistent, high-purity powders |
| Praxair Surface Tech. | Aluminum, Copper | $100 – $200 | Wide range of particle sizes |
| Carpenter Technology | Cobalt-Chromium, Tantalum | $250 – $400 | Specialized for medical devices |
| Höganäs | Stainless Steel, Titanium | $180 – $280 | Excellent for additive manufacturing |
| Tekna | Aluminum, Zirconium | $120 – $220 | High sphericity, uniform particles |
| LPW Technology | Inconel, Titanium | $200 – $320 | Aerospace and automotive focused |
| Metal Powder & Process | Nickel, Magnesium | $140 – $240 | High purity, various grades |
| Aubert & Duval | Titanium, Cobalt-Chromium | $220 – $350 | Superior quality, custom orders |
| Arcam AB | Stainless Steel, Aluminum | $130 – $210 | Ideal for 3D printing |
Pros and Cons, Advantages and Limitations of Plasma Atomisation
| Aspect | Advantages | Limitations |
|---|---|---|
| Quality | High purity, uniform particle size | High cost of equipment |
| Consistency | Spherical particles, repeatability | Requires skilled operators |
| Flexibility | Can produce a variety of metals | Limited by feedstock quality |
| Applications | Suitable for high-tech industries | High initial investment |
| Efficiency | Efficient material usage | Complex process control |
| Performance | Superior mechanical properties | Higher operational costs |
| Scalability | Scalable for large productions | Equipment maintenance |
| Control | Precise control over particle size | Sensitive to process parameters |
Detailed Analysis of Specific Metal Powder Models
Let’s take a closer look at specific metal powder models produced through plasma atomisation, their characteristics, and their applications.
Titanium (Ti) Powder
Composition: 99.9% Titanium
Properties:
- High strength-to-weight ratio
- Excellent corrosion resistance
- Biocompatibility
Applications: Aerospace components, medical implants, automotive parts
Characteristics:
- Spherical shape
- High purity
- Uniform particle size distribution
Specifications:
- Size Range: 15-45 µm, 45-90 µm
- Grades: CP1, CP2, CP3, CP4
- Standards: ASTM F67, F136
Suppliers: AP&C, Höganäs, Carpenter Technology
Pricing: $200 – $300 per kg
Pros: High performance in critical applications, superior mechanical properties
Cons: High cost, sensitive to contamination during production
Inconel (Ni-Cr Alloy) Powder
Composition: 60% Nickel, 23% Chromium, others
Properties:
- High-temperature strength
- Ox
idation resistance
- Good mechanical properties
Applications: Gas turbine components, heat exchangers, 3D printing
Characteristics:
- Fine, spherical particles
- High purity
- Uniform size
Specifications:
- Size Range: 15-53 µm, 53-150 µm
- Grades: IN718, IN625
- Standards: AMS 5662, AMS 5663
Suppliers: AP&C, LPW Technology, Sandvik
Pricing: $200 – $320 per kg
Pros: High performance at elevated temperatures, good corrosion resistance
Cons: Expensive, requires careful handling
Stainless Steel (316L) Powder
Composition: 17% Chromium, 12% Nickel, 2.5% Molybdenum
Properties:
- Corrosion resistance
- Good mechanical properties
- Biocompatibility
Applications: Medical implants, food processing equipment, marine applications
Characteristics:
- Uniform particle size
- Spherical shape
- High purity
Specifications:
- Size Range: 15-45 µm, 45-105 µm
- Grades: 316L, 304L, 17-4PH
- Standards: ASTM A276, A240
Suppliers: Höganäs, Sandvik, Arcam AB
Pricing: $150 – $250 per kg
Pros: Versatile, widely used in various industries
Cons: Relatively high cost, may require specific handling conditions
Aluminum (Al) Powder
Composition: 99.7% Aluminum
Properties:
- Lightweight
- Good electrical and thermal conductivity
- High reflectivity
Applications: Automotive parts, aerospace components, electronics
Characteristics:
- Fine, spherical particles
- High purity
- Uniform size distribution
Specifications:
- Size Range: 20-63 µm, 63-150 µm
- Grades: 6061, 7075
- Standards: ASTM B209, B221
Suppliers: Praxair Surface Tech., Tekna, Arcam AB
Pricing: $100 – $200 per kg
Pros: Lightweight, versatile in various applications
Cons: Oxidizes easily, requires protective atmosphere during processing
Copper (Cu) Powder
Composition: 99.9% Copper
Properties:
- Excellent electrical and thermal conductivity
- Malleability
- Corrosion resistance
Applications: Electrical components, heat exchangers, additive manufacturing
Characteristics:
- Uniform shape
- High purity
- Fine particles
Specifications:
- Size Range: 15-45 µm, 45-90 µm
- Grades: OFC, ETP
- Standards: ASTM B170, B187
Suppliers: Praxair Surface Tech., Metal Powder & Process, Sandvik
Pricing: $100 – $200 per kg
Pros: Excellent conductivity, versatile in electronic applications
Cons: Relatively high cost, requires specific storage conditions
Cobalt-Chromium (Co-Cr) Powder
Composition: 55% Cobalt, 30% Chromium, others
Properties:
- High wear resistance
- Corrosion resistance
- Biocompatibility
Applications: Medical implants, dental prosthetics, aerospace components
Characteristics:
- High sphericity
- Fine particle size
- High purity
Specifications:
- Size Range: 10-45 µm, 45-90 µm
- Grades: CoCrMo, CoCrW
- Standards: ASTM F75, F1537
Suppliers: Carpenter Technology, Aubert & Duval, Höganäs
Pricing: $250 – $400 per kg
Pros: Excellent for medical and dental applications, high durability
Cons: Expensive, requires specialized handling
Tantalum (Ta) Powder
Composition: 99.9% Tantalum
Properties:
- High melting point
- Corrosion resistance
- Biocompatibility
Applications: Medical implants, aerospace components, electronics
Characteristics:
- Spherical particles
- High purity
- Fine size distribution
Specifications:
- Size Range: 15-45 µm, 45-150 µm
- Grades: R05200, R05400
- Standards: ASTM B521, B708
Suppliers: Carpenter Technology, Höganäs, Tekna
Pricing: $250 – $400 per kg
Pros: High performance in extreme conditions, excellent corrosion resistance
Cons: Very expensive, limited availability
Nickel (Ni) Powder
Composition: 99.9% Nickel
Properties:
- Corrosion resistance
- Good mechanical properties
- High conductivity
Applications: Batteries, electronics, aerospace components
Characteristics:
- Uniform, spherical particles
- High purity
- Consistent size distribution
Specifications:
- Size Range: 15-53 µm, 53-150 µm
- Grades: 200, 201
- Standards: ASTM B160, B162
Suppliers: Metal Powder & Process, Sandvik, AP&C
Pricing: $140 – $240 per kg
Pros: Versatile, widely used in high-tech industries
Cons: Expensive, requires careful handling
Magnesium (Mg) Powder
Composition: 99.8% Magnesium
Properties:
- Lightweight
- Good machinability
- Moderate strength
Applications: Automotive parts, aerospace components, electronics
Characteristics:
- Fine particles
- High purity
- Uniform size distribution
Specifications:
- Size Range: 15-45 µm, 45-105 µm
- Grades: AZ31, AZ61
- Standards: ASTM B107, B90
Suppliers: Metal Powder & Process, Höganäs, Praxair Surface Tech.
Pricing: $140 – $240 per kg
Pros: Lightweight, good for high-volume production
Cons: Flammable, requires special handling
Zirconium (Zr) Powder
Composition: 99.9% Zirconium
Properties:
- High corrosion resistance
- Biocompatibility
- Good mechanical properties
Applications: Medical devices, nuclear reactors, aerospace components
Characteristics:
- Spherical, fine particles
- High purity
- Consistent size distribution
Specifications:
- Size Range: 10-45 µm, 45-105 µm
- Grades: 702, 705
- Standards: ASTM B551, B493
Suppliers: Tekna, Höganäs, Arcam AB
Pricing: $120 – $220 per kg
Pros: Excellent for medical and nuclear applications, high corrosion resistance
Cons: Expensive, requires careful handling
FAQs
| Question | Answer |
|---|---|
| What is plasma atomisation? | Plasma atomisation is a process that uses a plasma torch to melt metal feedstock, which is then atomized into fine droplets. |
| Why is plasma atomisation important? | It produces high-quality metal powders with uniform particle size and high purity, essential for high-tech applications. |
| What metals can be atomised using this method? | Metals like titanium, Inconel, stainless steel, aluminum, copper, cobalt-chromium, tantalum, nickel, magnesium, and zirconium. |
| What are the applications of these powders? | They are used in aerospace, medical, automotive, electronics, additive manufacturing, and more. |
| What are the benefits of plasma atomisation? | High purity, uniform particle size, spherical shape, and suitability for critical applications. |
| What are the limitations of plasma atomisation? | High cost of equipment, requires skilled operators, and sensitive to process parameters. |
| Who are the major suppliers of these powders? | AP&C, Sandvik, Praxair Surface Tech., Carpenter Technology, Höganäs, Tekna, LPW Technology, Metal Powder & Process, Aubert & Duval, Arcam AB. |
| How do the costs of these powders compare? | Prices vary depending on the metal, ranging from $100 to $400 per kg. |
Conclusion
Plasma atomisation stands out as a revolutionary process for producing high-quality metal powders, essential for advanced manufacturing technologies. By offering superior control over particle size, shape, and purity, this technique meets the stringent demands of industries like aerospace, medical, and electronics. Whether you’re looking to create lightweight aerospace components, biocompatible medical implants, or high-performance electronics, plasma-atomised powders provide the precision and quality needed for these critical applications.
