Powder Metallurgy (PM) is efficient in material utilization, energy consumption, and environmental impact, making it key for future carbon neutrality. The maturation of PM and the trend towards miniaturization in components have boosted Metal Injection Molding (MIM) and 3D Printing (AM). However, the supply of high-quality powder materials has become a major constraint.
Traditional Press Forming is suitable for large, simple-shaped products with medium-low density and lower requirements for metal powders. Smaller and more complex parts are better suited for injection molding and 3D printing, increasingly used in high-end fields like aerospace, medical, electronics, and military. This has increased the demand for metal powders with high purity, good sphericity, small particle size, narrow distribution, and low oxygen content.
Powder Production Methods and Nozzles:
1. Atomization Methods: The carbonyl method for iron and nickel powders has been replaced by water, gas, oil atomization, gas-water combined atomization, and plasma atomization. Nozzles are crucial, affecting atomization rate, production efficiency, and powder quality. Improving nozzle design can enhance these aspects, but nozzles face severe conditions like erosion and thermal shock, impacting stability and lifespan.
2. Zirconia Ceramic Nozzles: Widely used due to high-temperature stability and wear resistance but have issues with atomization uniformity and blockages.
3. Boron Nitride Ceramic Nozzles: Offer excellent high-temperature performance, reduced blockages, consistent particle size distribution, and strong thermal shock resistance, allowing use without extensive preheating.
3D Printing and Nozzles:
3D printing, unlike molding, suits personalized production. Brass nozzles are common for conventional polymer materials but unsuitable for high-temperature materials and high-precision printing.
Boron Nitride in 3D Printing: Boron nitride’s benefits in metal atomization apply to 3D printing, addressing high-temperature challenges and ensuring rapid metal solidification.
Advantages of Boron Nitride Nozzles
1. High-Temperature Performance: Suitable for high-temperature metal processing.
2. Low Friction and Smooth Surface: Reduces blockages and ensures consistent particle size distribution.
3. Thermal Shock Resistance: Can be used without extensive preheating, enhancing durability.
4. Corrosion and Wear Resistance: Extends nozzle lifespan and improves process stability.
5. Consistent Performance: High precision in manufacturing ensures batch consistency.
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