New Refractory Metal Powder Atomization System Developed
Researchers in the United States, specifically at Ames Laboratory, are advancing a new refractory metal powder atomization system aimed at enhancing the development of materials designed for high-performance applications, such as gas turbines and fusion energy systems. Ames Lab Scientist Jordan Tiarks highlights the lab’s legacy in creating specialized powders that are unmatched elsewhere.
Expanding Capabilities in Material Processing
The new system represents a significant technological leap, operating at processing temperatures up to 3400 °C and achieving production rates of up to one kilogram per minute. This innovation addresses a crucial need in the U.S. industry for high-melting-temperature alloys, enabling the precise manufacturing of complex components that conventional methods struggle to produce.
Addressing Industry Needs
Currently, gas turbines used in the aerospace sector are made from nickel- or cobalt-based superalloys, requiring substantial cooling systems and expensive thermal barrier coatings to function efficiently at high temperatures. There is ongoing research for new alloys capable of withstanding extreme conditions without the extensive cooling requirements. Tiarks notes the previous challenges teams faced when attempting to procure powders for testing, which often resulted in long wait times.
Innovative Atomization Process
The atomization system at Ames Lab utilizes a transferred arc plasma process that melts the feedstock locally before atomization, improving safety and material purity. This process allows for flexibility in feedstock form, enabling the use of various materials. Notably, the melting occurs in a water-cooled copper hearth, creating a protective “skull” layer, which insulates the molten material from the cooler environment. This method enables the use of only a small volume of material at high temperatures, thus ensuring better control over the material properties.
Enhancing Research Capabilities
The refractory atomizer enhances Ames Lab’s existing suite of atomization systems, which cater to different material processing needs. While the refractory atomizer may result in lower yields for high-temperature alloys (10%-20%), it complements more conventional systems that achieve much higher yields for alloys processed at lower temperatures.
This advancement positions Ames Laboratory at the forefront of materials research, significantly accelerating the development and adoption of innovative materials within the U.S. industry.
