EP1543172B1 - Reinigung von metallpartikeln durch hitzebehandlung - Google Patents
Reinigung von metallpartikeln durch hitzebehandlung Download PDFInfo
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- EP1543172B1 EP1543172B1 EP03753690A EP03753690A EP1543172B1 EP 1543172 B1 EP1543172 B1 EP 1543172B1 EP 03753690 A EP03753690 A EP 03753690A EP 03753690 A EP03753690 A EP 03753690A EP 1543172 B1 EP1543172 B1 EP 1543172B1
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- particles
- metal
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- pellets
- heat source
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- 238000000746 purification Methods 0.000 title claims abstract description 14
- 239000002923 metal particle Substances 0.000 title claims description 10
- 238000000034 method Methods 0.000 claims abstract description 104
- 229910052751 metal Inorganic materials 0.000 claims abstract description 79
- 239000002184 metal Substances 0.000 claims abstract description 79
- 239000002245 particle Substances 0.000 claims abstract description 65
- 239000012535 impurity Substances 0.000 claims abstract description 39
- 238000004519 manufacturing process Methods 0.000 claims abstract description 31
- 238000002844 melting Methods 0.000 claims abstract description 20
- 230000008018 melting Effects 0.000 claims abstract description 20
- 238000001816 cooling Methods 0.000 claims abstract description 16
- 238000004663 powder metallurgy Methods 0.000 claims abstract description 12
- 238000011946 reduction process Methods 0.000 claims abstract description 8
- 238000009834 vaporization Methods 0.000 claims abstract description 6
- 239000012798 spherical particle Substances 0.000 claims abstract description 5
- 239000000843 powder Substances 0.000 claims description 44
- 239000008188 pellet Substances 0.000 claims description 35
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 26
- 239000010936 titanium Substances 0.000 claims description 24
- 229910052719 titanium Inorganic materials 0.000 claims description 22
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 16
- 238000010438 heat treatment Methods 0.000 claims description 14
- 229910045601 alloy Inorganic materials 0.000 claims description 13
- 239000000956 alloy Substances 0.000 claims description 13
- 239000008187 granular material Substances 0.000 claims description 13
- 239000007787 solid Substances 0.000 claims description 5
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims description 4
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 claims description 4
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 4
- 229910052791 calcium Inorganic materials 0.000 claims description 4
- 239000011575 calcium Substances 0.000 claims description 4
- 239000001110 calcium chloride Substances 0.000 claims description 4
- 229910001628 calcium chloride Inorganic materials 0.000 claims description 4
- 238000010894 electron beam technology Methods 0.000 claims description 4
- 229910052749 magnesium Inorganic materials 0.000 claims description 4
- 239000011777 magnesium Substances 0.000 claims description 4
- 238000009835 boiling Methods 0.000 claims description 3
- 238000004320 controlled atmosphere Methods 0.000 claims description 3
- 230000006698 induction Effects 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 2
- 238000010891 electric arc Methods 0.000 claims 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 11
- 229910001069 Ti alloy Inorganic materials 0.000 description 8
- 239000007789 gas Substances 0.000 description 7
- 150000002739 metals Chemical class 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 6
- 229910044991 metal oxide Inorganic materials 0.000 description 6
- 150000004706 metal oxides Chemical class 0.000 description 6
- 150000003839 salts Chemical class 0.000 description 6
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 239000000356 contaminant Substances 0.000 description 5
- 239000001301 oxygen Substances 0.000 description 5
- 229910052760 oxygen Inorganic materials 0.000 description 5
- 238000007796 conventional method Methods 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- 239000003792 electrolyte Substances 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 229910052786 argon Inorganic materials 0.000 description 3
- 239000007795 chemical reaction product Substances 0.000 description 3
- 238000001704 evaporation Methods 0.000 description 3
- 230000008020 evaporation Effects 0.000 description 3
- -1 for example Substances 0.000 description 3
- 229910052757 nitrogen Inorganic materials 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000007858 starting material Substances 0.000 description 3
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 3
- 239000004408 titanium dioxide Substances 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 238000013019 agitation Methods 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 239000002826 coolant Substances 0.000 description 2
- 238000004090 dissolution Methods 0.000 description 2
- 238000005868 electrolysis reaction Methods 0.000 description 2
- 238000005242 forging Methods 0.000 description 2
- 239000001307 helium Substances 0.000 description 2
- 229910052734 helium Inorganic materials 0.000 description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 2
- 239000011261 inert gas Substances 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000005339 levitation Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 150000002736 metal compounds Chemical class 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 229910002065 alloy metal Inorganic materials 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000005660 chlorination reaction Methods 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000001513 hot isostatic pressing Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B34/00—Obtaining refractory metals
- C22B34/10—Obtaining titanium, zirconium or hafnium
- C22B34/12—Obtaining titanium or titanium compounds from ores or scrap by metallurgical processing; preparation of titanium compounds from other titanium compounds see C01G23/00 - C01G23/08
- C22B34/1295—Refining, melting, remelting, working up of titanium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B34/00—Obtaining refractory metals
- C22B34/10—Obtaining titanium, zirconium or hafnium
- C22B34/12—Obtaining titanium or titanium compounds from ores or scrap by metallurgical processing; preparation of titanium compounds from other titanium compounds see C01G23/00 - C01G23/08
- C22B34/129—Obtaining titanium or titanium compounds from ores or scrap by metallurgical processing; preparation of titanium compounds from other titanium compounds see C01G23/00 - C01G23/08 obtaining metallic titanium from titanium compounds by dissociation, e.g. thermic dissociation of titanium tetraiodide, or by electrolysis or with the use of an electric arc
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/14—Refining in the solid state
Definitions
- This invention relates to a method for the purification of metal particles, for example, metal powders and other finely sized metal samples, and, in particular, to ones that have been produced by the process of electrochemical reduction of metal compounds.
- the invention is particularly suited to the purification of titanium powder formed from the electrolytic reduction of titanium oxide TiO 2 .
- WO 99/64638 describes methods for the electrolytic reduction (or "electro-reduction") of metal compounds. Certain embodiments of those methods involve the electrolysis of metal oxides or other compounds in a cell containing a liquid (fused salt) electrolyte and an anode, the metal oxide forming or contacting the cathode. Conditions are controlled so as to bring about the selective dissolution of the oxygen of the cathode in preference to deposition of the metal cation of the fused electrolyte. The metals extracted by such methods, however, often require further purification.
- GB2359564 is directed to improved methods for carrying out such processes, particularly to produce powdered titanium, and some of those methods are summarised below:-
- Sintered granules or powders of metal oxide can be used as the feedstock for the electrolysis described in the above referenced method, as long as appropriate conditions are present.
- powdered titanium dioxide in the form of granules or a powder is used, the powdered particles preferably having a size in the region of 200 ⁇ m.
- the granules of titanium dioxide 1 are held in a basket 2 below a carbon anode 3 located in a crucible 4 having a molten salt 5 therein. These are prevented from sintering together by maintaining particle motion by any appropriate method e.g. in a fluidised bed arrangement.
- Agitation is provided either by mechanical vibration or by the injection of gas underneath the basket. Mechanical vibration can, for example, be provided by ultrasonic transducers mounted on the outside of the crucible or on control rods.
- the key variables to be adjusted are the frequency and amplitude of the vibrations in order to get an average particle contact time which is long enough to get reduction, but short enough to prevent diffusion bonding of the particles into a solid mass. Similar principles would apply to agitation by the injection of gas, except here the flow rate of the gas and size of the gas bubbles would be the variables controlling particle contact time.
- a metal is deposited onto a cathode (based on the electrolytic process previously described) from a second source of the metal at a more positive potential, the resulting metal deposited thereon is dendritic in structure. This is particularly so where the metal is titanium.
- This form of titanium is easy to break up in to a powder as individual particles are connected together only by a small surface area.
- This method can be used to produce titanium powder from titania. In this method, illustrated in Figure 2 , a second cathode 6 is provided which is maintained at a potential that is more negative than the first cathode 7.
- Continuously feeding a fine powder of metal oxide into the electrochemical cell allows for a constant current and a higher reaction rate.
- a carbon electrode is preferred for this method. This method permits the use of cheaper feedstock as a sintering and/or forming stage is no longer needed.
- FIG. 3 shows a conducting crucible 1 which is made the cathode containing a molten salt 2 and inserted therein is an anode 3. Titanium dioxide powder 4 is fed into the crucible where it undergoes reduction and is deposited at the base of the crucible.
- the thick arrow shows the increasing thickness of the reduced feedstock 5.
- the purity of the metal powder may be affected by the starting materials and processing parameters used. For example, it has been found that some variations of the method when used to produce titanium powder result in powder that contains "contaminating impurities" resulting wherefrom, including light metals such as magnesium or calcium, as well as salts such as calcium chloride (the latter being a preferred electrolyte). Such impurities are known to affect the mechanical properties of alloyed metal components, for example, salt inclusions are known to affect the fatigue performance and weldability of titanium alloys.
- a method for purifying metal M 1 particles manufactured by an electrochemical reduction process comprising the steps of:
- the present invention thus provides a method for purifying electrochemically reduced metal particles so as to reduce or remove the aforementioned "contaminating impurities" introduced by the reduction process, so as to enable, for example, direct use of the electrolytically reduced metals in lower temperature powder metallurgy processes.
- the kinds of impurities introduced by such electro-reduction processes are usually more volatile than the metal M 1 and may be conveniently removed by the present process.
- Such impurities may comprise light metals, for example, calcium and magnesium, as well as salts from the electrolyte, such as calcium chloride.
- the impurities should preferably be more volatile than the metal M 1 by at least a factor of ten, or preferably 20, in terms of their respective vapour pressures at the processing temperature.
- the processing temperature and/or heating time should be sufficient to remove substantially all the contaminating impurities, for example, so as to reduce their total level to less than 50 ppm, or less than 10% their initial total concentration.
- the process is conducted so that there is little or no evaporation (for example, less than 5%) of the metal M 1 .
- metal powders produced by electrolytic reduction of oxide or oxides are desirable, and a fully dense spherical particle morphology is preferred, for example in order to impart good flowability.
- the particles may only be partially melted in order to remove said impurities, in most cases the particles need to be fully melted to achieve dense, spherical particles.
- the heat source is arranged such that the metal particles may be allowed to free fall through the heat source.
- Suitable heat sources include but are not strictly limited to a hot plasma torch, a hot gas flame, a tube furnace, an induction coil, electric arcs and lasers.
- the particles may be blown through a plasma torch into the flame and allowed to free fall into a collecting vessel.
- the torch is preferably arranged at a sufficient height above the vessel such that any portion of the particles that is melted by the heat source is substantially solidified before collection. This prevents distortion of the shape of the particles.
- the established method of levitation melting may be used to hold particles of powder in a surrounding heat source for a period sufficient to vaporise the impurities.
- zero gravity processing may be used. The common purpose of these embodiments is to suspend the particles individually in mid-air, out of contact with any surfaces, so as to enable particles to be heated and melted and resolidified individually, without contact with each other, or a container.
- the temperature of the heat source should be at or above the melting point of the metal M 1 .
- the desired point is about 1680°C and for titanium alloys approximately 1500-1800°C.
- an argon or helium arc plasma torch can achieve temperatures sufficient to melt titanium powder particles entrained in the flame.
- the process is conducted in a controlled atmosphere, for example, at low pressure/vacuum and/or in an inert atmosphere.
- the powder particles are kept separate from oxygen or nitrogen while above a temperature of about 500°C. This is achieved in practice either by processing in a vacuum or in an atmosphere of Ar.
- the method is applicable to all metals and alloys provided a temperature sufficient to melt the particles and volatise the contaminants can be achieved.
- the step of removing the impurities may simply involve allowing them to be swept away by the gas flow from the flame of the heat source.
- the step of removing the impurities involves condensing the vaporised impurities on cold collector plates positioned adjacent the hot gas flame and disposing of the condensed impurities. Additionally, if the contaminants re-condense onto the surfaces of the powder particles M 1 , then they can be removed easily with a water or dilute acid wash.
- the inventors have appreciated that by exposing small particles of a metal M 1 to a heat source at around or above the melting point, but below the boiling point of M 1 , and allowing them to fall freely through the heat source, the shape of the particles can be altered to a near spherical shape. Spherical particles provide improved bonding in powder metallurgy processes.
- the temperature of the heat source used in the purification process of the method is substantially equal to or higher than the melting point of M 1 but lower than the boiling point of M 1 .
- Powdered particles purified in accordance with the method of the invention may be used in the formation of alloy metal articles made by various powder metallurgy methods and will provide improved particle bonding and mechanical properties in the alloyed article.
- the invention provides a method for the manufacture of a metal article containing a metal M 1 , by purifying metal M 1 particles as set out in the first aspect of the invention above and performing a powder metallurgy process on the particles to form the article.
- the temperature of the heat source will be substantially equal to or above the melting point of the metal M 1 .
- the electrochemical reduction method may comprise any suitable electro-reduction method for the production of metal particles, and includes the methods described herein or as described in WO 99/64638 .
- the powder metallurgy process used may be any conventional powder metallurgy process including but not limited to powder sintering and/or forging.
- powder sintering and/or forging One example of such a process is hot isostatic pressing.
- Purified powders made according to the first aspect of the invention may be used in various other processes for the manufacture of metal articles where powdered starting materials are desirable.
- M 1 may be construed to mean a single metal or a combination of different metals formed in a single method.
- References to particles may be construed to mean a powder or other finely sized metal samples, for example, granules or pellets, that could be purified by the present method.
- a powder may be construed to comprise small particles up to about 1mm in diameter.
- Figures 1 to 3 show, by way of example, three suitable prior art arrangements for producing metal powders by electrolytic reduction, and are discussed in more detail above.
- FIG 4 shows a preferred arrangement for purifying a powder in which the particles are blown through a plasma torch into a flame and allowed to free fall into a collecting means.
- the reactor 10 comprises a large metal vessel 11, provided with an inert atmosphere 12, which is preferably argon dispensed from jets 9.
- an inert atmosphere 12 which is preferably argon dispensed from jets 9.
- the metal particles (M 1 ) enter the vessel from a supply hopper 14 through the plasma torch 13, which is attached and sealed to the top of the vessel 11 so that it points downwards, and provides sufficient heat to melt and vaporise the metal particles and contaminants, respectively, as they pass through the upper section of the vessel 11.
- the torch 13 is preferably arranged at a sufficient height above the collecting means that any portion of the particles that is melted by the heat source is substantially solidified before collection. This prevents distortion of the shape of the particles.
- the re-solidified powder is collected and sealed into a metal collection hopper 15 via a funnel cyclone collector 16.
- levitation melting is used to hold particles of powder in a surrounding heat source for a period sufficient to vaporise the impurities.
- the apparatus comprises a supply hopper 14 through which metal particles (M 1 ) enter via a valve 24 into a large ceramic tube-like chamber 23.
- the powder is allowed to fall through the ceramic tube under its own weight.
- an external concentric electromagnetic induction coil 22 Around the mid-section of the chamber 23 is an external concentric electromagnetic induction coil 22, which both heats and levitates the metal powder particles such that they spend sufficient time at a suitable temperature for volatile contamination removal and spheroidisation to take place.
- the purified powder then falls to the bottom of the chamber 23, cooling sufficiently to solidify, before exiting via valve 25 and being collected and sealed into a metal canister 15.
- an inert gas flow is introduced counter to the direction of the metal powder flow via inlet 21 and outlet 20, and this both enhances the cooling of the powder particles at the lower end of the tube, and also helps to carry away volatile species.
- An electro-reduction process also known as an electro-deoxidation (EDO) process, is less expensive and easier to perform than conventional metal extraction methods.
- Metal particles produced by an EDO process may advantageously be used directly as feedstocks in manufacturing processes that incorporate the present purification process as an integral stage.
- Such a manufacturing process has, in particular, significant benefits over conventional processes for the production of titanium articles.
- Conventional methods for the manufacture of titanium and titanium alloy stock involve hot working of large titanium alloy ingots. The high temperatures and pressures required for these processes contribute to the high cost of this stock compared to other metal products such as steel and aluminium alloys.
- Titanium is conventionally obtained from its ore by the Kroll route, a complex chlorination and magnesium reduction method.
- the purified metal granules, called sponge are then melted with the alloying additions and cast into large titanium alloy ingots.
- the metal is melted at least twice and sometimes more, in order to ensure chemical homogeneity and freedom from defects.
- the large titanium alloy ingots are then hot forged repeatedly to produce the semi-finished alloy stock shapes, such as bar, plate, sheet and wire, required for the manufacture of articles.
- the present invention aims to provide novel methods for the manufacture of titanium or other metal alloy stock, which are less expensive and easier to perform.
- the above-mentioned manufacturing process incorporating the purification stage may involve:
- pellets should be heated sufficiently to allow them to coalesce to form a sheet when subjected to the pressure of the nip, and may be heated so that they soften, or, at least partly melt, or even fully melt.
- pellet covers particles ranging from powders to granules.
- either or both of the feed rollers are water cooled by passing a coolant through their centres.
- a coolant is water, other suitable fluids will no doubt occur to the skilled addressee.
- the above-mentioned manufacturing process incorporating the purification stage may involve:
- the sheet or cast stock may be allowed to cool or may be actively cooled.
- the alloy pellets may be obtained by an electro-deoxidation process such as that described in WO 99/64638 , or, in the Applicant's co-pending applications GB2359564 or GB2362164 . As is described in the above specifications, electrochemical reduction may be used to provide small pellets of alloy having high purity and good grain structure. Thus, heating and purification involving softening or partially melting the pellets is sufficient to bond the pellets and obtain a mass of alloy having good mechanical properties.
- the step of heating the pellets is preferably carried out by means of an energy beam.
- the energy beam may, optionally, be selected from an electron beam, a laser or a plasma torch.
- the processing temperature and/or heating time should be sufficient to remove substantially all the contaminating impurities, for example, so as to reduce their total level to less than 50 ppm, or less than 10% their initial total concentration.
- the process is conducted so that there is little or no evaporation (for example, less than 5%) of the metal.
- the process is conducted in a controlled atmosphere, for example, at low pressure/vacuum and/or in an inert atmosphere.
- a controlled atmosphere for example, at low pressure/vacuum and/or in an inert atmosphere.
- Ti it is important that the powder particles are kept separate from oxygen or nitrogen while above a temperature of about 500°C. This is achieved in practice either by processing in a vacuum or in an atmosphere of Ar.
- the use of argon or helium arc torches is particularly preferred.
- the rolled or cast stock may be further processed, for example, by one or more additional intermediate steps such as further working or heat treatments of the stock, prior to final cooling.
- Products of the methods are comprised of fully dense metal alloy.
- the homogeneity of the final metal is improved considerably because the pellets are provided via an electrochemical reduction method, as compared to the alternative of using Kroll sponge and powder or particles of the alloy additions.
- the present methods require considerably less cumbersome and costly apparatus compared to conventional methods where the starting materials are introduced to the casting or rolling apparatus fully molten and are particularly suited to the production of small quantities of stock where mechanical properties and metal homogeneity are of importance.
- the present methods are particularly suited to the manufacture of low volume or small size products, which could be prohibitively costly to produce by conventional methods.
- pellets of titanium metal or alloy 31 are delivered through a hopper 32 to a pair of counter-rotating feed rollers 33a, 33b.
- the rollers are cooled by a water-cooling system (not shown).
- An energy beam 34 is arranged to concentrate a beam of energy along a line just above the nip of rollers 33a, 33b and causes at least partial melting of the pellets seated on and between the rollers.
- the rollers 33a, 33b rotate, the at least partially melted pellets are drawn into the nip and are squeezed together to form a solid mass of the titanium or titanium alloy in the form of a sheet 35.
- the hot sheet falls to a conveyor 36 and is carried away for further processing and/or cooling.
- Figure 7 illustrates a similar arrangement for the production of bar stock having a square cross-section.
- a source of pellets 41 is delivered through a hopper 42 to a shallow crucible 47.
- a laser 44 is mounted on a track 48 along which the energy beam sweeps back and forth.
- the energy beam is aimed at the top surface of the crucible 47 and causes at least partial melting of the pellets 41 delivered thereto.
- the metal is drawn through a square shaped die 49 communicating with a lower surface of the crucible 47 and bar stock 45 of the titanium or titanium alloy emerges.
- the bar stock may be cut to length by a cutter (not shown).
- the bar stock is collected by a conveyor system 46 and removed for cooling and/or further processing.
- the feedstock in the form of pellets is stored inside a hopper that is an integral part of a vacuum chamber housing the roller and for example, E-beam (electron-beam) or a laser beam melting assembly.
- E-beam electron-beam
- the vacuum chamber is desirably at a pressure ranging from 1 x 10 -6 to 1 x 10 -5 mBar during the operation.
- the energy beam directed at the pellets heats and at least partially melts the titanium feedstock between the roller gap, which either softens it sufficiently for it to be deformed and consolidated as it passes through the roll gap, or melts it then solidifies it instantaneously on contacting the rollers and also gets deformed into a strip subsequently.
- the temperature of the solid strip coming out of the rollers is in the region of 600°C.
- This method is not specific only to titanium feedstock, it has potential application for direct production of strips of any metallic powder, and especially those that are very sensitive to the absorption of impurities such as oxygen or nitrogen.
- the method of manufacture of strip described above is ideally suited to feed stock of uniformly sized granules of less than about 1 mm dimensions. Larger granules may be optimal for production of thicker sheets by this method.
- Rollers are desirably cooled through the centre.
- the primary requirement is that the chamber housing the rollers should be in a vacuum (or very low pressure environment) to stop the molten titanium from picking up oxygen.
- a water-cooled roller assembly has been developed by the applicants that lets the water flow through the rollers and bearings, while maintaining good vacuum tightness.
- the heating is conducted so as simultaneously to remove all or part of any volatile contamination that may be present in the feed material, for example, EDO granules may contain contaminants such as calcium chloride, calcium oxide or calcium metal.
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- Metallurgy (AREA)
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- Life Sciences & Earth Sciences (AREA)
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Claims (26)
- Verfahren zum Reinigen von Partikeln eines Metalls M1, die mit einem elektrochemischen Reduktionsverfahren hergestellt wurden, wobei das Verfahren die folgenden Schritte beinhaltet:Einleiten der Partikel des Metalls M1 in eine Wärmequelle, so dass die Partikel mit keinen Flächen in Kontakt sind, bei einer Temperatur, die im Wesentlichen gleich oder höher als der Schmelzpunkt von M1 ist, um zu bewirken, dass die vorhandenen kontaminierenden Verunreinigungen teilweise oder im Wesentlichen ganz verdampfen;Beseitigen der verdampften Verunreinigungen aus der Nähe der Partikel;und Kühlen der gereinigten Partikel des Metalls M1, um sie in fester Form aufzufangen.
- Verfahren zur Herstellung eines Metalllegierungsartikels, der ein Metall M1 enthält, durch Reinigen der Partikel des Metalls M1 mit dem Verfahren von Anspruch 1 und Ausführen eines Pulvermetallurgieverfahrens an den Partikeln zum Bilden des Artikels.
- Verfahren nach Anspruch 2, wobei der Artikel ein Metalllegierungsartikel ist und wobei die gereinigten M1-Partikel mit Partikeln anderer Legierungskomponenten gemischt werden und das Pulvermetallurgieverfahren an dem Gemisch zum Bilden des legierten Artikels ausgeführt wird.
- Verfahren nach Anspruch 1, 2 oder 3, wobei die Partikel in Form eines Pulvers vorliegen.
- Verfahren nach Anspruch 4, wobei das Pulver Partikel mit einem Durchmesser von bis zu etwa 1 mm umfasst.
- Verfahren nach Anspruch 1, 2 oder 3, wobei die Partikel in Form von fein bemessenen Metallproben, Körnern oder Pellets vorliegen.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Partikel, wenn sie mit keinen Flächen in Kontakt sind, in der Luft suspendiert und/oder frei an der Wärmequelle vorbei oder darin fallen gelassen werden.
- Verfahren nach einem der Ansprüche 1 bis 6, wobei die Partikel, wenn sie mit keinen Flächen in Kontakt sind, in einer Flamme mitgeführt oder durch einen Plasmabrenner geblasen werden oder sich innerhalb einer Induktionsspule befinden.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Partikel erhitzt, geschmolzen und im Wesentlichen ohne Kontakt mit Flächen wieder verfestigt werden.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Freifalldistanz von der Wärmequelle ausreicht, damit von der Wärmequelle geschmolzenes Metall M1 vor dem Auffangen erneut verfestigen kann.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Wärmequelle ausgewählt wird aus der Gruppe bestehend aus einem Plasmabrenner, einem Laser, einem Lichtbogen, einer Induktionsspule oder einem Rohrofen.
- Verfahren nach einem der vorherigen Ansprüche, wobei das Verfahren in einer geregelten Atmosphäre ausgeführt wird.
- Verfahren nach einem der vorherigen Ansprüche, das in einer Vorrichtung ausgeführt wird, die eine Wärmequelle, ein Auffangmittel zum Auffangen der gereinigten Partikel und ein separates Auffangmittel zum Auffangen der Verunreinigungen beinhaltet.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Wärmequelle ein Plasmabrenner ist und der Schritt des Entfernens der verdampften Verunreinigungen das Wegreißenlassen der Verunreinigungen durch den Heißgasfluss von dem Brenner beinhaltet.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Temperatur der Wärmequelle um oder über dem Schmelzpunkt, aber unter dem Siedepunkt von M1 liegt.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Partikel von Metall M1 zur Reinigung durch ein elektrochemisches Reduktionsverfahren hergestellt werden.
- Verfahren nach einem der vorherigen Ansprüche, wobei M1 Titan umfasst.
- Verfahren nach einem der vorherigen Ansprüche, wobei die Verunreinigungen Magnesium, Calcium und/oder Calciumchlorid beinhalten.
- Verfahren zur Herstellung eines Metalllegierungsartikels mit gleichförmigem Querschnitt, das die folgenden Schritte beinhaltet:Zuführen eines kontinuierlichen Vorrats von Pellets aus einer Metalllegierung M1, die kontaminierende Verunreinigungen enthalten, die flüchtiger sind als M1, zu einem Verarbeitungsmittel;Erhitzen der Pellets bei ihrer Annäherung an das Verarbeitungsmittel durch freien Fall durch eine Wärmequelle bis auf eine Temperatur, die im Wesentlichen gleich oder höher als der Schmelzpunkt von M1 ist, um eine Verdampfung von einigen oder im Wesentlichen allen der vorhandenen kontaminierenden Verunreinigungen zu bewirken;Entfernen der verdampften Verunreinigungen aus der Nähe der Pellets;Ziehen des Metalls durch das Verarbeitungsmittel, um die Pellets zu dem gewünschten Artikel zu koaleszieren; undKühlen des gegossenen Produkts.
- Verfahren nach Anspruch 19 zur Herstellung eines Metalllegierungsblechs, das die folgenden Schritte beinhaltet:Zuführen des kontinuierlichen Pelletvorrats zu einem Paar gekühlten Zuführungswalzen;Erhitzen der Pellets gemäß Anspruch 19 bei ihrer Annäherung an den Walzenspalt des Zuführungswalzenpaares;Ziehen des Metalls durch den Spalt der Walzen, um ein Metalllegierungsblech zu bilden; undKühlen des Blechs.
- Verfahren nach Anspruch 19 zur Herstellung eines Metalllegierungsmaterials mit gleichförmigem Querschnitt, das die folgenden Schritte beinhaltet:Zuführen des kontinuierlichen Pelletvorrats aus der Metalllegierung zu einem gestalteten Schmelztiegel;Erhitzen der Pellets nach Anspruch 19 bei ihrer Annäherung an die exponierte Oberfläche des Schmelztiegels;Ziehen des wenigstens teilweise geschmolzenen Metalls von einer gegenüberliegenden Fläche des Schmelztiegels durch eine Düse, wobei die Nettoform und die Nettoabmessungen des Querschnitts der Düse nahezu der/den gewünschten Nettoform und -abmessungen des gewünschten Materials entsprechen; undKühlen des Gussteils.
- Verfahren nach einem der Ansprüche 19 bis 21, wobei der Schritt des Erhitzens der Pellets mit einem Energiestrahl ausgeführt wird, der aus einem Elektronenstrahl, einem Laser oder einem Plasmabrenner ausgewählt wird.
- Verfahren nach einem der Ansprüche 19 bis 21, wobei die Legierung im Wesentlichen Titan umfasst.
- Verfahren zur Herstellung von gereinigten Metallpartikeln, die sphärische Partikel mit einer reduzierten Konzentration der flüchtigen Verunreinigungen unter Anwendung eines Verfahrens nach einem der Ansprüche 1 bis 18 beinhaltet.
- Verfahren nach Anspruch 24, wobei die Konzentration der flüchtigen Verunreinigungen weniger als 50 ppm beträgt.
- Verfahren nach Anspruch 24 oder 25, wobei die Konzentration der flüchtigen Verunreinigungen weniger als 10% der Konzentration vor dem Reinigen ausmacht.
Applications Claiming Priority (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0222219A GB0222219D0 (en) | 2002-09-25 | 2002-09-25 | Purification process |
| GB0222219 | 2002-09-25 | ||
| GB0222358 | 2002-09-26 | ||
| GB0222348A GB2393450A (en) | 2002-09-26 | 2002-09-26 | Method of Manufacture of Metal Alloy Stock |
| GB0222348 | 2002-09-26 | ||
| GB0222358A GB2393451A (en) | 2002-09-26 | 2002-09-26 | A Method of Manufacture of Metal Alloy Sheet |
| PCT/GB2003/004093 WO2004029332A2 (en) | 2002-09-25 | 2003-09-24 | Purification of electrochemically deoxidised refractory metal particles by heat processing |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| EP1543172A2 EP1543172A2 (de) | 2005-06-22 |
| EP1543172B1 true EP1543172B1 (de) | 2009-12-16 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| EP03753690A Expired - Lifetime EP1543172B1 (de) | 2002-09-25 | 2003-09-24 | Reinigung von metallpartikeln durch hitzebehandlung |
Country Status (6)
| Country | Link |
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| US (2) | US20060130610A1 (de) |
| EP (1) | EP1543172B1 (de) |
| AT (1) | ATE452214T1 (de) |
| AU (1) | AU2003271852B2 (de) |
| DE (1) | DE60330577D1 (de) |
| WO (1) | WO2004029332A2 (de) |
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| JP4754488B2 (ja) * | 2003-08-28 | 2011-08-24 | テクナ・プラズマ・システムズ・インコーポレーテッド | 粉末材料の合成や分離や精製のための方法 |
| EP1671711A1 (de) * | 2003-10-09 | 2006-06-21 | Ebara Corporation | Verfahren zur reinigung von durch schwermetall verunreinigtem material und vorrichtung dafür |
| RU2370559C1 (ru) * | 2008-06-26 | 2009-10-20 | Вадим Георгиевич Глебовский | Способ получения высокочистого титана для распыляемых мишеней |
| KR102322229B1 (ko) | 2014-05-13 | 2021-11-05 | 더 유니버시티 오브 유타 리서치 파운데이션 | 실질적으로 구형인 금속 분말의 제조 |
| KR20170101927A (ko) | 2014-12-02 | 2017-09-06 | 더 유니버시티 오브 유타 리서치 파운데이션 | 금속 분말의 용융 염 탈산소화 |
| CN107208978B (zh) * | 2015-10-22 | 2019-08-23 | 株式会社Posco | 原料装载设备、冷却辊及防止粘附矿石产生的方法 |
| HUE065423T2 (hu) | 2015-12-16 | 2024-05-28 | 6K Inc | Eljárás szferoidális dehidrogénezett titánötvözet részecskék elõállítására |
| US10987735B2 (en) | 2015-12-16 | 2021-04-27 | 6K Inc. | Spheroidal titanium metallic powders with custom microstructures |
| US11077497B2 (en) | 2017-06-07 | 2021-08-03 | Global Titanium Inc. | Deoxidation of metal powders |
| AU2019290663B2 (en) | 2018-06-19 | 2023-05-04 | 6K Inc. | Process for producing spheroidized powder from feedstock materials |
| KR20240036705A (ko) | 2019-04-30 | 2024-03-20 | 6케이 인크. | 리튬 란타넘 지르코늄 산화물(llzo) 분말 |
| CA3134573A1 (en) | 2019-04-30 | 2020-11-05 | Sunil Bhalchandra BADWE | Mechanically alloyed powder feedstock |
| WO2021118762A1 (en) | 2019-11-18 | 2021-06-17 | 6K Inc. | Unique feedstocks for spherical powders and methods of manufacturing |
| US11590568B2 (en) | 2019-12-19 | 2023-02-28 | 6K Inc. | Process for producing spheroidized powder from feedstock materials |
| US11181325B2 (en) * | 2019-12-23 | 2021-11-23 | Valgroup S.A. | System for the production of molten salt used as a heat transfer medium for a pyrolysis system |
| AU2021297476A1 (en) | 2020-06-25 | 2022-12-15 | 6K Inc. | Microcomposite alloy structure |
| AU2021349358A1 (en) | 2020-09-24 | 2023-02-09 | 6K Inc. | Systems, devices, and methods for starting plasma |
| EP4237174A1 (de) | 2020-10-30 | 2023-09-06 | 6K Inc. | Systeme und verfahren zur synthese von sphäroidisierten metallpulvern |
| EP4275239A4 (de) | 2021-01-11 | 2024-12-18 | 6K Inc. | Verfahren und systeme zur rückgewinnung von li-ionen-kathodenmaterialien mittels mikrowellenplasmaverarbeitung |
| WO2022192394A1 (en) * | 2021-03-10 | 2022-09-15 | The Regents Of The University Of California | Gas-phase production of aligned metal nanoparticles using external magnetic fields |
| US20220324022A1 (en) * | 2021-03-31 | 2022-10-13 | 6K Inc. | Microwave plasma processing of spheroidized copper or other metallic powders |
| AU2022246797A1 (en) | 2021-03-31 | 2023-10-05 | 6K Inc. | Systems and methods for additive manufacturing of metal nitride ceramics |
| CN113999981A (zh) * | 2021-11-02 | 2022-02-01 | 广东先导微电子科技有限公司 | 一种高纯金属真空升华的除杂方法 |
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-
2003
- 2003-09-24 DE DE60330577T patent/DE60330577D1/de not_active Expired - Lifetime
- 2003-09-24 AT AT03753690T patent/ATE452214T1/de active
- 2003-09-24 US US10/529,234 patent/US20060130610A1/en not_active Abandoned
- 2003-09-24 WO PCT/GB2003/004093 patent/WO2004029332A2/en not_active Ceased
- 2003-09-24 AU AU2003271852A patent/AU2003271852B2/en not_active Ceased
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2012
- 2012-05-22 US US13/477,368 patent/US20120230860A1/en not_active Abandoned
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| Publication number | Publication date |
|---|---|
| ATE452214T1 (de) | 2010-01-15 |
| DE60330577D1 (de) | 2010-01-28 |
| US20060130610A1 (en) | 2006-06-22 |
| WO2004029332A3 (en) | 2004-10-21 |
| EP1543172A2 (de) | 2005-06-22 |
| AU2003271852A1 (en) | 2004-04-19 |
| US20120230860A1 (en) | 2012-09-13 |
| WO2004029332A2 (en) | 2004-04-08 |
| AU2003271852B2 (en) | 2010-03-11 |
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