Draft:Ultrasonic metal atomization

Ultrasonic Metal Atomization

Ultrasonic metal atomization is an advanced method for producing metallic powders and alloys, utilizing high-frequency ultrasonic waves to fragment molten metal into fine droplets. This technology has become a cornerstone in the production of high-quality powders for industries such as aerospace, automotive, medical devices, and Additive manufacturing (3D printing).

SEM photo of 316L Stainless Steel metal powder atomized with ATO Lab Plus ultrasonic metal atomizer

Physical Principles of Ultrasonic Atomization

The process of ultrasonic atomization relies on the interaction between acoustic waves generated by a piezoelectric emitter and a stream of molten metal. Key steps in the process include:

1. Generation of ultrasonic waves: High-frequency sound waves (typically in the range of 20–100 kHz) are generated by piezoelectric or magnetostrictive transducers.
2. Interaction with the molten metal stream: When the sound waves interact with the liquid metal, they induce intense oscillations that create localized pressure variations. These variations lead to the formation of capillary waves on the surface of the molten stream.
3. Droplet formation: As the amplitude of these oscillations increases, the capillary waves break up into droplets due to surface tension forces being overcome by the energy imparted by the sound waves.
4. Cooling and solidification: The droplets rapidly solidify into spherical particles as they cool in a controlled environment, such as a protective inert gas atmosphere.

The advantages of ultrasonic atomization include the production of powders with a highly spherical shape, narrow particle size distribution, and low levels of contamination. These characteristics make ultrasonic atomization particularly suitable for advanced manufacturing processes.

Development of Ultrasonic Atomization in Poland

The research into ultrasonic atomization accelerated in 2016, driven by the efforts of 3D Lab, a company specializing in advanced technologies for metal powders and additive manufacturing. Recognizing the growing demand for high-quality powders, especially for 3D printing applications, 3D Lab initiated an R&D program to develop proprietary ultrasonic atomization technology.

1. Initial research and prototyping (2016–2017): In 2016, 3D Lab, based in Warsaw, Poland, began its own R&D work focused on developing ultrasonic atomization. As a result of the research, the company filed its first patent application for an ultrasonic atomizer in 2017.
2. Continued work on ATO ultrasonic atomization technology (2017–2018): The first prototype was presented in November 2017 at the Formnext international trade fair in Frankfurt, Germany . 3D Lab showcased the world’s first compact ultrasonic atomizer, ATO One, which became the foundation of the ATO LAB system. Early work focused on the atomization of aluminum and aluminum-scandium alloys.
3. Crossing previously unavailable temperature barriers (2018–2019): 3D Lab achieved successful atomization of materials with higher melting points, including Stainless steel (316L), titanium alloys (e.g., Ti6Al4V, Ti Gr.5), and nickel-based superalloys (e.g., Inconel 718, Inconel 625).
4. World’s first installation of ultrasonic atomizer (2019): The first industrial installation of an ATO LAB ultrasonic atomizer occurred in 2019 at a company in the gas and oil sector.

   

   ATO Lab Plus ultrasonic metal atomizer with operator

5. Commercialization and patent protection (2021 onwards): 3D Lab patented its ultrasonic atomization process and began offering the technology to industrial clients. The system supports atomization of materials with melting points up to 3400 °C and can process input in the form of wire, rod, or scrap.

3D Lab also expanded its offering with periprocess solutions including vacuum furnaces, material cleaning systems, powder sieving machines, and part cleaning systems, creating a comprehensive ATO suite covering the full metal powder production workflow.

Industrial Applications

Ultrasonic atomization is used across various industrial sectors due to its ability to produce powders with superior quality and consistency:

• Additive manufacturing (3D printing): Spherical powders are ideal for LPBF and similar processes, improving powder flowability, packing density, and the mechanical properties of printed parts.
• Recycling and Sustainability: Enables atomization of scrap materials (e.g., aluminum chips), reducing waste and supporting circular economy principles.
• High-performance alloys: Enables atomization of complex materials such as nickel-based superalloys and titanium alloys used in aerospace and medical industries.
• Low-volume, high-value production: Well-suited for research and custom powder production.
• Integrated heating systems: Uses optimized induction or arc heating for precise control and reduced oxidation.
• Advanced process control: Real-time monitoring of ultrasonic parameters ensures consistency.
• Adaptable design: Supports a broad range of feed materials including lightweight alloys.
• Sustainability focus: Facilitates metal scrap reuse in line with global environmental goals.

Physical and Economic Impact

Ultrasonic atomization is transforming powder metallurgy and modern manufacturing by:

• Providing high material efficiency with minimal waste.
• Reducing environmental impact via scrap reuse.
• Enhancing production capabilities for advanced applications such as additive manufacturing.

The continued development of ultrasonic atomization underlines its importance in modern metal powder production and the growing emphasis on sustainability and efficiency in industry.