Novel Cold Crucible Ultrasonic Atomization Powder Production Method for 3D Printing
Description & AMAZEMET association
A novel ultrasonic atomization method uses a cold crucible atop a 20 kHz sonotrode to melt materials with an electric arc and pulverize them into spherical powders suitable for additive manufacturing. Testing with various alloys, including metallic glass, produced powders with tailored compositions and structures, with AMZ4 remaining amorphous below 50 μm. This method offers a promising approach for material scientists to develop high-quality powders efficiently.
Authors
Łukasz Żrodowski 1 2*,Rafał Wróblewski 1 *, Tomasz Choma 1 2,Bartosz Morończyk 1, Mateusz Ostrysz 1, Marcin Leonowicz 1, Wojciech Łacisz 1, Piotr Błyskun 1, Jan S. Wróbel 1, Grzegorz Cieślak 1, Bartłomiej Wysocki 3 4, Cezary Żrodowski 5 and Karolina Pomian 1
1 Faculty of Materials Science and Engineering, Warsaw University of Technology, Woloska 141 St., 02-507 Warsaw, Poland
2 AMAZEMET Sp. z o.o. [Ltd], Al. Jana Pawła II 27, 00-867 Warsaw, Poland
3 Center of Digital Science and Technology, Cardinal Stefan Wyszynski University in Warsaw, Woycickiego 1/3, 01-938 Warsaw, Poland
4 MaterialsCare LCC, Zwierzyniecka 10/1, 15-333 Bialystok, Poland
5 Faculty of Ocean Engineering and Ship Technology, Gdansk University of Technology, 80-233 Gdansk, Poland
* Authors to whom correspondence should be addressed.
Abstract
A new powder production method has been developed to speed up the search for novel alloys for additive manufacturing. The technique involves an ultrasonically agitated cold crucible installed at the top of a 20 kHz ultrasonic sonotrode. The material is melted with an electric arc and undergoes pulverization with standing wave vibrations. Several different alloys in various forms, including noble and metallic glass alloys, were chosen to test the process. The atomized particles showed exceptional sphericity, while powder output suitable for additive manufacturing reached up to 60%. The AMZ4 metallic glass powder remained amorphous below the 50 μm fraction, while tungsten addition led to crystallization in each fraction. Minor contamination and high Mn and Zn evaporation, especially in the finest particles, was observed in atomized powders. The innovative ultrasonic atomization method appears as a promising tool for material scientists to develop powders with tailored chemical composition, size and structure.
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