Comparison of the Performance and Cost of Water Atomized and Gas Atomized Alloy Powder
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The prices of other commodities like the Gas Atomized Alloy Powder are also expected to be volatile.
The powder preparation method in which a fast-moving fluid (atomizing medium)
impacts or otherwise breaks the metal or alloy liquid into fine droplets and
then condenses into a solid powder is called the atomization powdering method.
At present, the most widely used powdering technology is water atomization and
gas atomization. Although the principle of powdering is the same, the physical
properties of the powders produced vary greatly.
Since the heat capacity of gas is smaller than that of water, when gas
atomization is used, the alloy receives a low degree of chill. When the
atomization medium is impacted, the alloy liquid atomized into fine droplets
will not solidify immediately, which gives the alloy The time for the droplet to
shrink into a ball during the falling process, so it is easy to obtain spherical
alloy powder. When water is atomized, the situation is just the opposite. Due to
the chilling effect of water atomization into fine alloy droplets, it solidifies
into alloy powder almost in an instant. This makes the alloy powder formed by
alloys with lower surface tension appear as potatoes. Only those alloys with
high surface tension, such as nickel-based alloys, can be made into spherical
alloy powders. By adjusting the atomization parameters and the superheat of the
alloy liquid during atomization, water atomization can also be used to produce
approximately spherical alloy powders to meet the needs of thermal spraying.
No matter whether it is water atomization or gas atomization, the chemical
composition of the alloy powder produced will not be different due to the
different production methods.
The alloy powder made by gas atomization has a much lower degree of
supercooling than that made by water atomization. Therefore, the metallographic
structure of the alloy powder made by different atomization methods with the
same chemical composition will be different.
Oxygen content of alloy powder
The oxygen content of the alloy powder is related to the sensitivity of the
alloy itself to oxygen and the oxygen content in the atomization environment
during atomization. If the alloy itself is very sensitive to oxygen, not only
should measures be taken during atomization, it is best to use vacuum melting
during melting. For most alloys, as long as the contact with oxygen is reduced
during atomization, the purpose of reducing the oxygen content in the alloy
powder can be achieved. During gas atomization, nitrogen is usually used as the
atomization medium. A large amount of nitrogen fills the atomization area and
drives out the oxygen in the atomization area, so it can protect the alloy
droplets from being oxidized during atomization and cooling.
When a molten alloy liquid is atomized into metal powder, its surface area
increases countless times at the moment of atomization. In other words, its area
combined with oxygen increases, and more metal surfaces are exposed to it. In
the fogging environment. Therefore, if no measures are taken during water
atomization, the oxidation of the alloy droplets cannot be avoided. In order to
make the atomization environment less or anaerobic during water atomization,
first, the atomization cylinder must be sealed to isolate the atomization
environment from the surrounding environment. Secondly, it is necessary to
remove the oxygen in the closed atomization cylinder. Finally, such an
oxygen-free or low-oxygen atomization environment is maintained during the
atomization process, until the atomization is over, all the alloy droplets
solidify into alloy powder.
Production investment cost
The investment in equipment for water atomization and gas atomization is the
same. The investment for aerosolized cylinders is relatively large, but the
atomization medium working group-gas cylinders, meters and valves have a small
investment; water atomization is On the contrary, the input of the atomization
cylinder is smaller than that of the gasification, but the input of the
high-pressure water pump and the centrifugal water pump is greater than that of
the gas atomization atomization medium working group. In other parts, the
investment of the two is similar, and when combined, it is almost the same.
Unit alloy powder production cost
The production cost per kilogram of alloy powder is higher in gas atomization
than in water atomization. According to actual calculations, the cost of
atomizing medium is required for gas atomization to make one kilogram of alloy
powder. When water is atomized, the main energy consumed by the atomizing medium
is the electrical energy when the water pump is running. For this reason, gas
atomized alloy powders on the market are generally more expensive than water
atomized alloy powders.
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