Metal Powder Production by Atomization of Free-Falling Melt Streams Using Pulsed Gaseous Shock and Detonation Waves

A new method of producing metal powders for additive manufacturing by the atomization of free-falling melt streams using pulsed cross-flow gaseous shock or detonation waves is proposed. The method allows the control of shock/detonation wave intensity (from Mach number 4 to about 7), as well as the composition and temperature of the detonation products by choosing proper fuels and oxidizers. The method is implemented in laboratory and industrial setups and preliminarily tested for melts of three materials, namely zinc, aluminum alloy AlMg5, and stainless steel AISI 304, possessing significantly different properties in terms of density, surface tension, and viscosity. Pulsed shock and detonation waves used for the atomization of free-falling melt streams are generated by the pulsed detonation gun (PDG) operating on the stoichiometric mixture of liquid hydrocarbon fuel and gaseous oxygen. The analysis of solidified particles and particle size distribution in the powder is studied by sifting on sieves, optical microscopy, laser diffraction wet dispersion method (WDM), and atomic force microscopy (AFM). The operation process is visualized by a video camera. The minimal size of the powders obtained by the method is shown to be as low as 0.1 to 1 μm, while the maximum size of particles exceeds 400–800 μm. The latter is explained by the deficit of energy in the shock-induced cross-flow for the complete atomization of the melt stream, in particular dense and thick (8 mm) streams of the stainless-steel melt. The mass share of particles with a fraction of 0–10 μm can be at least 20%. The shape of the particles of the finest fractions (0–30 and 30–70 μm) is close to spherical (zinc, aluminum) or perfectly spherical (stainless steel). The shape of particles of coarser fractions (70–140 μm and larger) is more irregular. Zinc and aluminum powders contain agglomerates in the form of particles with fine satellites. The content of agglomerates in stainless-steel powders is very low. In general, the preliminary experiments show that the proposed method for the production of finely dispersed metal powders demonstrates potential in terms of powder characteristics.