Generation of small batch high quality metal powder

As part of a project to develop a small batch metal atomisation system, based on free fall atomisation and close-coupled atomisation, the influence of the process parameters on various powder quality features has been investigated, using copper–tin alloys as feedstock material. Particle size distribution, appearance of satellite particles, particle circularity and the flowability were recorded as criteria of particle quality. From the data obtained in these experiments, the effects of the main process parameters (atomisation pressure, mass melt flow, and height of the spray chamber as well as the atomiser system) have been evaluated with respect to powder quality features. The atomisation system was optimised to produce high quality powder with narrow particle distributions (d84·3/d50·3 = 1·6 for free fall) and high circularity with mass melt flows in the range of 100 kg h−1 using melt volume between 100 and 1000 mL.