Metal Atomization and Spray Forming
The research field comprises the atomization of liquid metal melts under inert gas with different processes for the production of particles (for example for additive manufacturing) between 10 and 2000 µm as well as the spray forming of deposits (up to 100 kg unit weight) of different geometries. Due to the atomization and the resulting high total surface area of the droplets, solidification occurs in non-equilibrium and the microstructure and material properties differ considerably from cast materials.
This allows alloy boundaries to be shifted and new alloys, material composites, composite and gradient materials to be produced. New atomisation processes are developed, analysed and used for the production of metal powder and deposits. Thermal simulation of the processes supports process understanding and facilitates up-scaling. The experimental work includes investigations and developments of different base alloys (Sn, Al, Fe, Cu, Ni, Co, Si) and special alloys. The metal powders are investigated with respect to particle size distribution, particle shape and flowability and conditioned for subsequent processes (sieving, sifting, mixing).