Bột xử lý điện cực xoay plasma: Hướng dẫn toàn diện

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Plasma rotating electrode process (PREP) powder is a type of spherical powder made using the PREP method. PREP powders have unique properties that make them suitable for use in various applications like thermal spray coatings, metal additive manufacturing, and metal injection molding.

Some key features of PREP powder include:

  • Highly spherical morphology with smooth surface
  • Controlled microstructure with fine grain size
  • Low porosity and high density
  • Excellent flowability and spreadability
  • High packing density
  • Good blending characteristics
  • Capability to manufacture alloys and composites

PREP enables customization of powder characteristics like particle size distribution, composition, density, oxide content, and more. By controlling the PREP process parameters, powders can be engineered for specific application requirements.

Types of PREP Powders

Powder MaterialThành phầnKey Properties and Applications
Nickel alloyNiCr, NiCrAlY, NiCoCrAlYOxidation and corrosion resistance. Thermal spray coatings.
Cobalt alloyCoCr, CoCrAlY, CoNiCrAlYHigh temperature strength. Thermal spray coatings.
Thép không gỉ316L, 304LCorrosion resistance. Metal AM, MIM.
Thép công cụH13, P20High hardness. Metal AM, MIM.
Titanium alloyTi6Al4V, TiAlHigh strength-to-weight ratio. Biomedical implants, aerospace.
Copper alloyCuCrZrHigh thermal conductivity. Electronic applications.
Aluminum alloyALSI12Lightweight. Automotive components.
Tungsten alloyWNiFe, WCoHigh density. Radiation shielding.

Composition and Microstructure

PREP enables close control over powder composition and microstructural features:

  • Alloying elements can be modified to achieve desired properties
  • Microsegregation is minimized compared to gas atomization
  • Fine grained microstructure with uniform distribution of phases
  • Porosity and oxide content can be reduced to very low levels
  • Spherical morphology is maintained after alloying

Key Properties of PREP Powder

Tài sảnSự miêu tảNhững lợi ích
Phân phối kích thước hạtPREP can achieve narrow distribution with controlled d50.Ensures uniform melting and consistent properties.
Hình tháiHighly spherical shape, smooth surface.Excellent flow and packing density.
Mật độ rõ ràngCan be optimized based on requirements.Higher density improves powder spreading.
Khả năng chảyMeasured by Hall flowmeter method.Ensures uniform powder feeding and spreading.
Packing densityHigh packing density up to 60%.Maximizes volume fraction of metal powder in component.
Oxide contentOxide levels below 0.2% achieved.Reduces oxide inclusions in final part.
Cấu trúc vi môFine grained and homogeneous.Uniform property distribution in final part.
Surface chemistryChemistry precisely controlled.Oxide formation, wettability, and spreading optimized.

Applications of PREP Powder

PREP powder is used across various industries due to its specialized properties:

Lớp phủ phun nhiệt

  • Excellent flowability results in uniform feed rate and coating quality
  • Controlled particle size distribution optimizes melting and minimizes unmelted powder
  • Smooth surface morphology improves coating density and adhesion strength
  • Low oxide content prevents oxide inclusions in coating
  • Spherical shape gives higher deposition efficiency

Kim loại sản xuất phụ gia

  • High packing density allows more material per layer, reducing voids
  • Smooth surface morphology results in uniform melting and melt pool flow
  • Controlled particle size distribution prevents segregation issues
  • Low surface oxide enables good inter-particle bonding
  • Sphericity and flowability minimize powder feed problems

Đúc kim loại

  • High packing density maximizes sintered density
  • Uniform particle size distribution prevents segregation
  • Good flowability and compatibility results in homogenous mixing
  • Low oxide content prevents sintering defects
  • Controlled composition yields desired properties after sintering

Thông số kỹ thuật

Typical specifications for PREP powder:

Tham sốRange
Kích thước hạt10 – 150 micron
Phân phối kích thước hạtD10, D50, D90 can be controlled
Hình tháiHighly spherical ≥ 0.9
Mật độ rõ ràngUp to 60% of theoretical density
Hall flowability< 30 s/50 g
Oxide content< 0.2 wt%
Cấu trúc vi môFine grained < 10 microns
Surface chemistryO, C, N levels precisely controlled

Nhà cung cấp và giá cả

Some leading global suppliers of PREP powders are:

Nhà cung cấpVị trí
SandvikThụy Điển
HOÀN TOÀNHoa Kỳ
HöganäsThụy Điển
Nhóm bột CNPCTrung Quốc

Pricing for PREP powder varies based on:

  • Base metal (Ni, Co, steel)
  • Thành phần hợp kim
  • Phân phối kích thước hạt
  • số lượng đặt hàng
  • Level of customization

Indicative pricing ranges from $50/kg to $120/kg for common alloys. Custom alloys and particle size distribution can increase cost.

Comparison to Gas Atomized Powder

Tham sốPREP PowderBột nguyên tử khí
Hình dạng hạtCao hình cầuIrregular, satellites present
Oxide contentVery low <0.2%Typically 0.5-2%
Độ xốpNear fully denseCan have 10-20% porosity
Alloy homogenityXuất sắcSegregation prone
Khả năng chảyRất tốtLower due to satellites
Packing densityUp to 60%Typically 30-40%
Surface chemistryPrecisely controlledVariable based on process
Trị giáCao hơnLower capital cost

Advantages of PREP Powder

  • Excellent spherical morphology for flowability
  • Phân phối kích thước hạt được kiểm soát
  • Low porosity and oxide content
  • Alloy homogeneity and fine microstructure
  • Customizable composition and properties
  • High packing density for AM and MIM

Limitations of PREP Powder

  • Higher cost compared to gas atomized powder
  • Limited to smaller particle sizes, usually below 150 microns
  • Requires advanced process control and optimization
  • Limited production rate compared to gas atomization
  • Restricted to select base metals like Ni, Co, and steels

Các câu hỏi thường gặp

Q: What is plasma rotating electrode process (PREP) powder?

A: PREP powder is a highly spherical metallic powder produced using the PREP method which involves rotating an electrode in a plasma arc under precise control to achieve desired powder characteristics.

Q: What materials can be made into PREP powder?

A: Common materials include nickel, cobalt, stainless steel, tool steel, titanium, aluminum, and copper alloys. Other alloys and composites are also possible through PREP.

Q: What are the key advantages of PREP powder?

A: Key advantages are excellent sphericity and flowability, controlled particle distribution, low porosity and oxides, fine and uniform microstructure, customizable composition, and high packing density.

Q: What is PREP powder used for?

A: Major applications are thermal spray coatings, metal additive manufacturing, and metal injection molding due to its specialized properties.

Q: How is PREP powder different from gas atomized powder?

A: PREP powder has superior sphericity, lower oxides, less porosity, more homogenous composition and microstructure compared to gas atomized powder.

Q: Is PREP powder more expensive than gas atomized powder?

A: Yes, PREP powder typically costs more due to higher process complexity and control involved. But it offers significant performance advantages over gas atomized powder.

Q: What particle size is available for PREP powder?

A: The usual range is 10 to 150 microns. Both smaller and larger sizes are possible but less common. Particle size distribution can also be controlled as per requirements.

Q: Does PREP powder have limited alloy options?

A: PREP is most established for nickel, cobalt and stainless steel alloys. But ongoing process development is expanding the alloy systems possible, including reactive materials like titanium and aluminum.

Q: Can PREP powder be customized for specific applications?

A: Yes, customization is a key benefit of PREP. Particle characteristics and alloy composition can be tailored to meet requirements for thermal spray, AM, MIM, etc.

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