repowder
Cost savings and low inert gas consumption
No powder spraying (wall adhesion) is observed on the inner wall of the atomization chamber.
Enables rapid cleaning of the atomization chamber.
Product Introduction
Ultrasonic atomization powder-production equipment can efficiently process raw materials of any alloy and in any form—even small sample quantities—directly yielding metal powders with uniform properties. Whether for new-material R&D or small-batch pilot production, it swiftly meets powder-production needs. Moreover, the equipment supports the use of virgin raw materials or recycled scrap to fabricate prototype castings and powder-based prototypes for novel alloy systems. Leveraging rePOWDER’s patented technology, it enables the resource recovery and regeneration of failed print parts, excess powder, process waste, and discarded powder, reprocessing them into high-quality fine powders. This significantly reduces material costs, enhances material utilization, and provides an efficient, environmentally friendly, and integrated powder-production solution for alloy development and additive manufacturing.
Working principle of ultrasonic atomization: Ultrasonic atomization is a liquid–solid separation process in which ultrasonic vibrations are used to atomize the feed material into a powder. The underlying principle hinges on the relationship between vibration amplitude and the wettability of the material’s surface: when the vibration amplitude of the liquid film wetting the surface of the ultrasonic transducer exceeds a critical threshold, standing capillary waves are generated (Lierke et al., 1967); further increasing the amplitude disrupts the internal cohesive forces within the melt, causing it to be ejected in the form of fine droplets and ultimately yielding metallic powder.
PSD can be tuned by varying the ultrasonic frequency: (The resulting particle size is primarily determined by the ultrasonic frequency, but is also influenced by the physical properties of the liquid medium, such as its density.)
- A particle size of 20 kHz is suitable for electron beam melting (EBM) and direct energy deposition (DED), with d50 values ranging from 80 to 100 μm depending on the atomized material.
- A 40 kHz ultrasonic processor is suitable for laser powder bed fusion (LPBF) and sintering processes, enabling particle sizes with a d50 of 45–60 μm.
- A particle size of 60 kHz is suitable for laser powder bed fusion (LPBF), binder jetting (BJ), thermal spraying, and sintering technologies, enabling a d50 particle size in the range of 35–45 μm.
The resulting narrow particle size distribution (PSD) enables up to 80% of the manufactured powder to be used in specialized applications.
rePOWDER ultrasonic atomization powder-production equipment can flexibly process a wide range of feedstock forms, including wire stock, irregular raw materials, and long bars, and supports diverse processing routes—from wire and powder feed to manual powder feeding and arc-melting feed, as well as automated bar feeding—ultimately enabling the efficient production of high-quality metal powders with uniform particle size, thereby providing reliable support for advanced manufacturing and material recycling.
Leveraging advanced ultrasonic atomization technology, we can use a wide range of materials as feedstocks to produce high-performance, custom-made metal powders of superior quality. These powders can be tailored to your specific requirements, ensuring optimal performance in real-world applications. The figure below illustrates material systems that have already been validated for practical use, while additional new materials are continuously under development.
Two types of heat sources:
① Induction melting
Induction melting is typically used to process alloys with melting points as high as 1300°C, such as:
·Volatile materials with relatively low melting points that readily evaporate in a plasma, such as Sn, Zn, Mg, Pb, and Al alloys.
·Materials with high heat capacity and high thermal conductivity, such as Cu and other precious metals, including Ag–Au alloys.
Materials of any shape and form can be placed in the crucible, including final alloys, master alloys, or pure elements.
Under the influence of magnetic stirring, materials tend to alloy easily.
② Arc/Plasma Melting
Heating can be carried out in an inert or reactive atmosphere using an electric arc (TIG generator) or a focused plasma. The top feed and melting of the ultrasonic welding horn require the use of suitably selected materials to enhance its performance; this approach enables mechanical waves to be transmitted to the workpiece while minimizing external contamination.
Suitable for use in combination with materials of medium to high melting points, including:
·Iron-based alloy
·Ti, Ni, Pt, Ir-based alloys
· Refractory materials, such as W, Ta, V, Mo, Nb, and Re, as well as high-entropy alloys
·Metal matrix composites
Core Advantages and Features:
- Processing of any element or alloy: Ultrasonic atomization can be applied to a wide range of pure elements—such as Zn, Mg, Pt, Mo, and Ta—as well as to any alloy composition, including Mg–Li, CuSn6, TiTaZrRuCu, and others.
- Any form of raw material: Capable of atomizing chips, failed additively manufactured parts, damaged samples, bars, wires, powders, and more.
- Automated operation: A variety of automatic feeders—such as those for powders, bars, and wires—and automatic plasma cutting machines are available to make operation as simple as possible.
- Modularity and openness: The rePowder platform features a modular design, allowing new modules to be added at any time. All connections within the equipment comply with current standards (such as ISO-KF), enabling each customer to design and connect their own modules as needed.
- One device, multiple possibilities: The rePowder platform can perform a variety of process types using a single piece of equipment, including the preparation of new compositions, alloy homogenization, ultrasonic atomization, suction casting, and other options currently under development.
- Multiple alloys can be produced in a single day: This equipment is laboratory-scale, easy to clean, and allows for rapid material changes. Within a single day, multiple atomization runs can be performed on different alloys using various ultrasonic systems.
- Multiple applications: The resulting powder can be used in a variety of technologies, including additive manufacturing, sintering, thermal spraying, and catalysis.
- Recycling: This equipment can reprocess printed parts or waste materials into powder for further use in the desired applications.
- Low maintenance costs: This device requires only a very small amount of inert gas—approximately 10 liters per minute—and the cost of each atomization cycle is negligible.
- Various capacity options are available to meet specific requirements: Powders can be produced in quantities ranging from a few grams per day (e.g., for small-scale alloying or rare and expensive elements) to several kilograms per day (for wire processing or induction-based modular systems).
Equipment Parameters
| Heat source | Induction heat source | Arc/Plasma Heat Source | Dual heat source |
| Equipment footprint | Approximately 360 x 220 x 220 cm | Approximately 360 x 220 x 220 cm | Approximately 360 x 220 x 220 cm |
| Power Requirements | 380 VAC, 50 Hz, three-phase, 36 A per phase | 340 A at 40% (250 A at 100%) load | 380 VAC, 50 Hz, three-phase, 36 A per phase |
| Sphericity | 0.98, no shimmering powder | 0.98, no shimmering powder | 0.98, no shimmering powder |
| Minimum atomization powder-making start-up quantity | ≤100g | ≤100g | ≤100g |
| Supporting Materials | Including, but not limited to, alloy materials such as stainless steel, high-temperature alloys, titanium alloys, platinum–iridium and platinum–rhodium alloys, and high-entropy alloys. | Including, but not limited to, alloy materials such as stainless steel, high-temperature alloys, titanium alloys, platinum–iridium and platinum–rhodium alloys, and high-entropy alloys. | Including, but not limited to, alloy materials such as stainless steel, high-temperature alloys, titanium alloys, platinum–iridium and platinum–rhodium alloys, and high-entropy alloys. |
| Induction Atomization Unit | It consists of an electrical cabinet, an induction furnace, an induction atomization chamber, and a collection device. | Independent unit. Composed of an atomization chamber, vacuum and gas management system, powder feeder, plasma torch, transducer, vacuum manipulator, and a powder collection container with an airlock, among other components. | It consists of an electrical cabinet, an induction furnace, an induction atomization chamber, and a collection device. |
| Induction heat source melting temperature | ≥1300℃ | / | ≥1300℃ |
| Plasma heat source temperature | / | ≥3500℃ | ≥3500℃ |
Download Materials
In recent years, driven by the surging global demand for clean energy, high-efficiency energy-storage technologies have emerged as a research hotspot in the energy sector. Among these, latent-heat thermal energy storage (LHTES) has garnered significant attention due to its high energy density and excellent thermal stability. Recently, a joint team from the Norwegian University of Science and Technology and Warsaw University of Technology in Poland, among other institutions, published a groundbreaking study in the journal Results in Engineering: for the first time, they have successfully developed ultra-high-temperature phase-change material (PCM) microcapsules based on a silicon–iron eutectic alloy, with an operating temperature exceeding 1,200°C and an energy-storage density far surpassing that of existing technologies. This article will provide an overview of this cutting-edge advancement, covering its background, underlying technical principles, experimental results, and potential future applications.
With the rapid advancement of 3D printing (additive manufacturing) technology, the demand for high-performance metal powders is steadily increasing, particularly in industries such as aerospace, automotive, and medical. As a next-generation metal powder, titanium-based composite powder has emerged as a research hotspot due to its outstanding properties, including low density, high strength, and excellent corrosion resistance. However, conventional powder-production methods suffer from issues such as non-uniform particle size, severe agglomeration, and compositional heterogeneity, which limit their practical applications. Recently, an innovative ultrasonic atomization technique has offered a new solution to these challenges. This paper provides an in-depth exploration of the “Preparation and Performance Study of Multi-Scale Reinforced Titanium-Based Composite Powders via Ultrasonic Atomization,” proposed by Professor Dong Fuyu and his team at Shenyang University of Technology. It examines the process flow, microstructure, mechanical and functional performance, and future application prospects of this material.
In the aerospace sector, nickel-based superalloys have long been the material of choice for manufacturing critical engine components due to their outstanding high-temperature performance. With the rapid advancement of additive manufacturing technologies, the demand for high-quality nickel-based superalloy powders has grown increasingly urgent. However, conventional powder-production methods either fail to meet quality standards or suffer from low efficiency, posing significant challenges to the industry. Fortunately, a recent breakthrough by a team at Dalian University of Technology—the Self-Impact Ultrasonic Atomization (SIUA) method—has successfully overcome these bottlenecks, opening up a new avenue for the production of nickel-based superalloy powders.
This paper presents a recent research achievement: the preparation of powders using AMAZEMET’s rePowder ultrasonic atomization system. Through systematic design and microstructure control, an innovative aluminum alloy with high strength, high ductility, and excellent high-temperature resistance has been successfully developed, opening up new prospects for enhancing the performance of 3D-printed aluminum alloys.
With the continuous advancement of materials science, the demand for high-performance alloys with superior corrosion resistance and wear resistance is steadily increasing. This is particularly true in industries such as aerospace, energy, and electronics, where the performance requirements for coating materials are constantly rising. Traditional powder-production methods, including powder metallurgy and mechanical milling, are increasingly unable to meet the need for precise control and functionalization of complex materials. Against this backdrop, ultrasonic atomization—a green and highly efficient new powder-production technology—has gradually emerged as a focal point in the research and development of advanced materials.
This paper provides a detailed analysis of an innovative powder-production technique—ultrasonic vibration-assisted melt atomization—proposed by Professor Dong Fuyu and his colleagues at Shenyang University of Technology, with a focus on its application in the preparation of high-entropy alloy powders, particularly the research findings on the TiZrTa0.7NbMo high-entropy refractory alloy. The study offers new insights for the future development of high-temperature, high-strength materials.
Atomization Process of Indium Alloy
Ultrasonic Atomization Induction Melting
Atomization Powder Production Using Aluminum Alloy Vibration Sheets
Iridium ultrasonic atomization focused plasma
Ultrasonic Atomization Induction Melting of Metallic Glasses
Ultrasonic Atomization Arc Plasma Melting
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