Fabrication of spherical tungsten powder for AM and MIM from scrap resources. Institute of Non-Ferrous Metals Gliwice, Poland

Transcription

1 Fabrication of spherical tungsten powder for AM and MIM from scrap resources Institute of Non-Ferrous Metals Gliwice, Poland 1

2 Institute of Non-Ferrous Metals Gliwice, Poland Institute of Non-Ferrous Metals established in 1952 Headquarters in Gliwice Divisions: Light Metals Division in Skawina (near Cracow) Central Laboratory of Batteries and Cells in Poznań Division in Legnica 2

3 Institute of Non-Ferrous Metals (IMN) main research and development center of the Polish non-ferrous metals industry staff employed: o o R&D staff - almost 170 employees Technical and production sectors employees Areas of expertise: processing of non-ferrous ores and other mineral resources pyrometallurgy, hydrometallurgy analytical chemistry processing of metals and alloys materials engineering new materials processing of scraps and wastes environmental protection chemical power sources experimental plants 3

4 Department of Powder and Composite Materials The main area of activity: Development of powders for special applications Functional coatings Sintered materials Powders for AM Corrosion and erosion resistant Antibacterial Hard and superhard materials Energy harvesting: thermoelectrics, piezoelectrics Developement of plasma spheroidization Spheroidization of irregular powders Recycling

5 Spherical powders: Spheroidization by plasma process: Refractory metals: W, Mo, Re Titanium alloys: Ti6Al4V Chemical modification of surface recycling Powders obtained by chemical methods: - ultrafine Cu - Cu-graphene, - Cu-CNT, Ag-CNT, Cu-TiO 2 nanocomposites Mixtures/granulates/alloys: - Cu TiO2, - Cu-Ti - Mo-Re - Ni-Re, Co-Re - Thermoelectric materials (e.g. Bi2Te3, CoSb3 W powder Cu powder 50 µm O K 50 µm Cu K 50 µm Ti K Re coated NrCr alloy Cu-Graphene composite Cu- TiO 2 powder

6 Copper powders ad foams Nano-powders and micropowders with high porosity Foams Fabricated at low temperatures (below 200oC) Specific surface ~ 2m2/g Foam obtained at 180o

7 FST atmospheric plasma spraying system with F4 and 7MB plasma torches Prototype, laboratory scale plasma spheroidization system FCT-HPD5 Spark Plasma Sintering Furnace Tube and retort furnaces with air, protective or reducing atmosphere (hydrogene up to 100%) Ball mills(fritsch - Pulverisette 7, RETSCH - PM 400, CryoMill) Hydraulic presses (up to 380T) Technology equipment

8 Measurement techniques X-ray phase analysis X-ray diffractometer Seifert-FPM XRD 7 Microanalysis (microstructure and chemical composition in microscale) X-ray microanalyser JOEL JXA Density of powder materials - Micromeritics Accupyc II 1340, Specific surface & porosity Micromeritics 3Flex, Gemini 2360 Particle size distribution Fritsch Analysette 22 Nanotec System for characterization of thermoelectric materials - Linseis LSR-3

9 Application of plasma technique for fabrication of spherical tungsten powder for AM and MIM 9

10 Laboratory scale Plasma Spheroidization System Plasma torch Spheroidization chamber Pressure control unit Out coming gas filter Powder container 10

11 Upscaling of the Plasma Spheroidization System Pilot scale spheroidization system to be launched in Q

12 Recycling of Tungsten Valorization of tungsten wires (wastes from production of incandescent filaments): oxidation grain size engineering thermal reduction plasma spheroidization Other tungsten sources available e.g. from hydrometallurgical extraction of WC scraps 12

13 Properties of fabricated spherical tungsten powder W W W 40.0 W W 30.0 W W W W CPS Cumulative particle size distribution Chemical composition 13

14 Properties of fabricated spherical tungsten powder (2) Average content of impurities Tungsten powder C, ppm O, ppm N, ppm Cu, ppm reduced spheroidized <5 14

15 Currently running project Manufacturing of spherical powders from scraps for special applications Spheroidized Ti64 powder made from scraps 15

16 Thank you for your attention Instytut Metali Nieżelaznych ul. Sowińskiego Gliwice tel fax imn@imn.gliwice.pl