Plasma Atomisation

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.

Plasma Atomisation

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 PowderCompositionPropertiesCharacteristics
Titanium (Ti)99.9% TiHigh strength-to-weight ratio, corrosion-resistantSpherical shape, high purity
Inconel (Ni-Cr alloy)60% Ni, 23% Cr, othersHigh-temperature strength, oxidation-resistantFine, spherical particles
Stainless Steel (316L)17% Cr, 12% Ni, 2.5% MoCorrosion-resistant, good mechanical propertiesUniform particle size, spherical
Aluminum (Al)99.7% AlLightweight, good conductivityFine, spherical particles
Copper (Cu)99.9% CuExcellent conductivity, malleableUniform shape, high purity
Cobalt-Chromium (Co-Cr)55% Co, 30% Cr, othersWear-resistant, biocompatibleHigh sphericity, fine particle size
Tantalum (Ta)99.9% TaHigh melting point, corrosion-resistantSpherical particles, high purity
Nickel (Ni)99.9% NiCorrosion-resistant, good mechanical propertiesUniform, spherical particles
Magnesium (Mg)99.8% MgLightweight, good machinabilityFine particles, high purity
Zirconium (Zr)99.9% ZrHigh corrosion resistance, biocompatibleSpherical, fine particles

Applications of Plasma Atomisation Powders

ApplicationMetal Powder UsedPurpose
AerospaceTitanium, Inconel, AluminumHigh strength, lightweight components
Medical DevicesCobalt-Chromium, TitaniumBiocompatibility, strength
Additive ManufacturingStainless Steel, TitaniumConsistent, high-quality 3D printing
ElectronicsCopper, NickelExcellent conductivity
AutomotiveAluminum, MagnesiumLightweight, durable parts
Tooling and DiesInconel, Stainless SteelHigh wear resistance
JewelryGold, Silver, PlatinumHigh purity, aesthetic appeal
Energy SectorZirconium, TantalumHigh corrosion resistance
Consumer GoodsStainless Steel, AluminumDurability, aesthetic properties

Specifications, Sizes, Grades, Standards of Plasma Atomisation Powders

Metal PowderSize Range (µm)Grades AvailableStandards
Titanium (Ti)15-45, 45-90CP1, CP2, CP3, CP4ASTM F67, F136
Inconel (Ni-Cr alloy)15-53, 53-150IN718, IN625AMS 5662, AMS 5663
Stainless Steel (316L)15-45, 45-105316L, 304L, 17-4PHASTM A276, A240
Aluminum (Al)20-63, 63-1506061, 7075ASTM B209, B221
Copper (Cu)15-45, 45-90OFC, ETPASTM B170, B187
Cobalt-Chromium (Co-Cr)10-45, 45-90CoCrMo, CoCrWASTM F75, F1537
Tantalum (Ta)15-45, 45-150R05200, R05400ASTM B521, B708
Nickel (Ni)15-53, 53-150200, 201ASTM B160, B162
Magnesium (Mg)15-45, 45-105AZ31, AZ61ASTM B107, B90
Zirconium (Zr)10-45, 45-105702, 705ASTM B551, B493

Suppliers and Pricing Details

SupplierMetal PowderPrice Range (per kg)Notes
AP&CTitanium, Inconel$200 – $300High-quality, aerospace-grade
SandvikStainless Steel, Nickel$150 – $250Consistent, high-purity powders
Praxair Surface Tech.Aluminum, Copper$100 – $200Wide range of particle sizes
Carpenter TechnologyCobalt-Chromium, Tantalum$250 – $400Specialized for medical devices
HöganäsStainless Steel, Titanium$180 – $280Excellent for additive manufacturing
TeknaAluminum, Zirconium$120 – $220High sphericity, uniform particles
LPW TechnologyInconel, Titanium$200 – $320Aerospace and automotive focused
Metal Powder & ProcessNickel, Magnesium$140 – $240High purity, various grades
Aubert & DuvalTitanium, Cobalt-Chromium$220 – $350Superior quality, custom orders
Arcam ABStainless Steel, Aluminum$130 – $210Ideal for 3D printing

Pros and Cons, Advantages and Limitations of Plasma Atomisation

AspectAdvantagesLimitations
QualityHigh purity, uniform particle sizeHigh cost of equipment
ConsistencySpherical particles, repeatabilityRequires skilled operators
FlexibilityCan produce a variety of metalsLimited by feedstock quality
ApplicationsSuitable for high-tech industriesHigh initial investment
EfficiencyEfficient material usageComplex process control
PerformanceSuperior mechanical propertiesHigher operational costs
ScalabilityScalable for large productionsEquipment maintenance
ControlPrecise control over particle sizeSensitive 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

Plasma Atomisation

FAQs

QuestionAnswer
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.

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