Pulsed High Energy Synthesis of Fine Metal Powders

Demand for micrometer size metal powders is increasing rapidly as new technologies emerge which can make use of their unique characteristics. One rapidly growing application requiring such powders is metal injection molding, a powder metallurgy process for forming near-net-shape components with higher dimensional accuracy than earlier processes. A significant need also exists for micrometer size soft magnetic alloy powders for use in low mass radar absorption coatings. In addition, the speed at which compacts are sintered in conventional powder metallurgy is increased as powder dimensions are reduced, and the sintering temperature is reduced, leading to faster, cheaper manufacturing of advanced materials. The finer microstructure which results can also improve the physical properties of parts made from finer powders. An innovative new approach to producing 1-10 um sized metal powders is proposed with the potential to dramatically decrease the cost of production. The process uses a repetitively pulsed high stagnation pressure gas jet to atomize a continuous melt stream. In Phase I, a Proof-of-Principle experiment will be performed making copper powder and an engineering design for a Phase II laboratory pre-production prototype will be made.