Novel System for Upcycling Metal Powders

By Dr. Cameron Chai and Peter Airey

For those involved with in metal additive manufacturing disposing of metal powders has been an environmental issue. That was until Amazemet, an innovator in metal powder production introduced their novel Powder2Powder atomisation system at Formnext in November. This system allows you to transform scrap or out-of-spec powder into new usable satellite-free powder with excellent sphericity and narrow particle size distribution, ideal for re-using.

Amazemet achieves this using unique technology that combines plasma processing and ultrasonic atomisation. Unlike plasma spheroidisation, the P2P technology allows powder size to be independent of the initial feedstock, making it the only technology capable of direct atomisation of pulverised Ti-feedstock.

Extensive trials using +200 μm oversize and irregular Ti alloy powders have shown exceptional results with the P2P system. Operating at a frequency of 40 kHz, the system consistently achieved a powder morphology with an aspect ratio (D50) exceeding 0.95. The particle size distribution (PSD) was precisely controlled, producing powders with D90 < 80 μm and yielding particles <63 μm at ≥80%. Nearly 97% of the resulting powder was suitable for AM processes, including Laser Powder Bed Fusion (LPBF), Directed Energy Deposition (DED), and Electron Beam Melting

(EBM), highlighting the system’s potential to enhance sustainability in metal powder production.

The P2P system can be used to create customised prealloyed powders with precise compositional control by blending elemental powders. This capability is invaluable for both research and industrial applications. This patented technology addresses two critical challenges in the AM industry - upcycling of powder waste and custom powder production - delivering advanced functionality that surpasses traditional recycling methods.

For more details, visit axt.com.au