The Importance of a Powder Production Line

The Importance of a Powder Production Line

Powder metallurgy is an innovative production method that offers superior tolerances and intricate shapes. It also reduces the need for machining, improving surface finish and providing repeatable accuracy.

The process uses a variety of techniques and equipment. From atomization to sintering, specialized machinery is used for each step of the powder metal production line.

Processes

Metals are transformed into a powder through various processing methods. This allows metal parts to be created without the need for subtractive processes, reducing material losses and saving money. The process is known as powder metallurgy (PM).

PM can produce highly complex metal components and has grown in popularity. It is an environmentally friendly production method because nearly all the powder that enters the process becomes part of the finished product. It is also energy efficient and uses very little water.

The powder is then consolidated to reduce voids, increase density, and make the final product workable. This is done by pressing the powder under high pressure. It is important that the powder compacting pressure matches the specifications of the part to ensure that the final product meets dimensional requirements.

There are several methods for producing the metal powder used in Powder Production Line PM, including gas atomization, induction melting, and plasma rotating electrode atomisation (PREP). In addition to these methods, some Additive Manufacturing techniques use water atomization.

It is crucial to test the powder for chemistry, particle size distribution, apparent density, and packing density. Generally, this data is documented on the powder test certificate. It is important to remember that the chemistry of the built metal will not match the original powder chemistry since it is easy to change alloy properties during manufacturing.

Equipment

The most important element of a successful powder production line is the equipment used to transform ingredients into finished product. The equipment must be designed and built for flexibility, accuracy, gentle product handling, and user-friendliness. JBT’s powder processing equipment is the favorite of major global brands because it makes achieving operational goals like quality targets, throughput, and minimizing downtime effortless.

In Powder Metallurgy, metals are turned into powder through one of several processes: solid-state reduction, atomization, electrolysis, and chemical treatments. These powders are blended with alloying elements to achieve the desired material properties for a specific application. Typically, they are then compacted to form high-strength, cost-effective components.

Compression is done in a powder compacting machine that uses a powerful spring to crush the particles filling machinery into a dense mass. Isostatic pressures of up to 15,000 psi (100,000 kPa) for most metals are common. This creates an isostatic compact with density up to 5% to 10% higher than wrought or cast parts made by traditional processes.

The resulting product can be further processed through sintering, machining, immersion oil, tempering, and/or metallurgy coatings to achieve the desired final part characteristics. The powder can also be treated by laser sintering as a part of additive manufacturing. This process binds the powder to produce a solid structure, much like traditional sintering, but with added benefits of reduced cycle times and dimensional consistency.

Maintenance

A powder production line needs regular maintenance to ensure it continues to operate at peak efficiency. Unplanned downtime can result in costly food spoilage, production delays, missed shipment deadlines, and increased environmental incidents. The good news is that preventive maintenance procedures can help reduce these issues.

A large powder manufacturer recently moved to a new facility in an older industrial building and soon began to experience both production and product quality issues. These problems were quickly traced back to the plant’s water supply system.

The plant uses 600 gallons per minute of water to cool various process lines in the plant as well as for other functions. The water is pumped through an extensive series of tanks to provide the different temperatures needed for the powder coating process and then recirculated through the plant. The water is filtered as it moves through the systems, removing sediment that would otherwise cause equipment damage or production problems.

The powder coating equipment must also be regularly cleaned and inspected. For instance, the spray nozzles and deflectors will suffer from wear from the abrasive powder over time. Additionally, the throat in the powder pump and the powder outlet tube will also become worn over time. This will decrease the efficiency of the gun and reduce the amount of powder being applied. To address these issues, the powder producers are implementing a program to replace these wear items before they become completely worn out.

Safety

Powder coating protects metal surfaces from corrosion and offers a more pristine finish. It is useful in manufacturing industries, such as automotive and aerospace. However, powder coating processes involve a variety of health and safety risks. This is why it’s important to understand the hazards associated with the powder coating process and take precautions accordingly.

One of the most common dangers of powder production lines is combustible dust explosions. These accidents can be deadly and can cause significant damage to processing plants. Fortunately, many plants can prevent these disasters by following NFPA 654 regulations for the handling of combustible solids.

This requires a mix sensor platform with efficient PSD measurement from which secondary bulk process variables can be inferred, such as flow rate and bulk density. This is a complex task and requires real-time sensing of both the physical and chemical characteristics of the powder mixture, which are not always well understood and can be difficult to measure reliably in-process.

This is why it’s important to choose a supplier with broad material-handling expertise. This can help you find solutions for challenges that may arise during the powder processing process, such as reducing the risk of explosions in powder and bulk transfer. Automated systems also reduce workers’ exposure to dangerous powder dust, making for a safer workplace and healthier environment.