Apparatus for producing metal powder

Abstract: Disclosed is an improved apparatus for producing metal powder by gas-atomizing method. The apparatus comprises a molten metal holding vessel (1) of bottomed cylinder shape, a molten metal discharging runner (2) installed at the bottom of the vessel, and a molten metal spraying device (4) having gas-jetting nozzles (42) in a spraying chamber (41) connected to the lower end of the runner; and is characterized in that the apparatus is provided with an induction heating coil (6) of a smaller diameter or the second heating coil surrounding the runner in addition to an induction heating coil (5) of a larger diameter or the first heating coil surrounding the vessel (1); that the nozzle part of the runner (2) is a sliding gate (6) made of a ceramics; that a ring-­ shaped magnetic shielding plate (27) made of an electroconductive and non-magnetic material is disposed between the induction heating coil (5) of a smaller diameter and the sliding gate (6); and that the shielding plate is equipped with a cooling means. The magnetic shielding plate (7) is preferably a hollow body and cooled by cooling water running therethrough. The atomizing can be begun and ended instantaneously at any time. The flux from the heating coil does not extend to the sliding gate of the discharging runner, and the sliding gate will not be heated and no loss of the flux therein occurs. In a preferred embodiment, there is used the molten metal holding vessel comprising a body made by lining refractory materials on the inner wall of a shell of a non-­ electroconductive and gas-impermeable material and a lid which can be gas titely jointed to the body. A vacuum generating means is connected to the lid. This apparatus gives clean powder metal without contamination with oxygen in the air.

Description: The invention concerns an apparatus for producing metal powder comprising a molten metal holding vessel of bottomed cylinder shape, a molten metal discharging runner installed at the bottom of the vessel, a molten metal spraying device having gas-jetting nozzles in a spraying chamber connected to the lower end of the runner and a first and second heating coils, the first having an induction heating coil of relatively large diameter surrounding the vessel and the second having a smaller diameter induction heating coil surrounding the runner. The apparatus according to the present invention for producing metal powder by gas-atomizing method is particularly useful for producing powder of special steels and super alloys, and it is possible to produce very clean metal powder with a preferable embodiment of this apparatus. Powder metallurgy has been often used for production of tools from a high-speed steel or sintered hard alloys of a high carbon content, or production of parts of a jet-engine or a gas-turbine with a Ni-based or a Co-based super alloy. By recent progress in HIP technology and spread of the equipments of large capacities, it is getting easier to produce the parts of desired shapes and performance starting from the metal powders. As a method of producing metal powder of low impurity contents, it has been known to atomize the molten metal with a jetting gas. The gas-atomizing method is carried out by using a molten metal atomizing apparatus of the type mentioned in the beginning and disclosed e.g. in DE-A-37 32 365, comprising a molten metal holding vessel equipped with a molten metal discharging runner at the bottom thereof and a spraying chamber equipped with gas-jetting nozzles therein. There was proposed further to use a discharging runner equipped with a sliding gate at the lower end of the runner connected to the bottom of the vessel and an induction heating coil around the runner. In the discharging runner mentioned above, when the metal in the runner is heated with the magnetic flux given by the induction coil surrounding the runner, it is often observed that the magnetic flux extends to the sliding gate to cause heating of the gate. Therefore, it is necessary to choose a heat-resistant material or a non-electroconductive material as the material of the gate. Also, consumption of the magnetic flux or loss of the electric power is inevitable at the gate. If the distance is so large that the magnetic flux from the coil may not extend to the gate, then it will be possible that the molten metal solidifies in the runner. With respect to the quality of the product metal powder, while practice of HIP at a higher temperature under a higher pressure gives products having bulk densities substantially the same as those of the ingot products, demand for better material metal powder is getting severer. In order to fully enjoy the merits of using powder metal, i.e., fine crystal grains, and fine precipitation and uniform distribution of the strengthening material such as carbides, it is necessary that the metal powder contains a very small amount of surface oxides and freee from external impurities such as pieces of refractories or slags. The powder metal products produced by conventional gas-atomizing technologies are not satisfactory. An object of the present invention is to provide an apparatus for producing metal powder by gas-atomizing method, which is equipped with a molten metal discharging runner, in which the sliding gate is not influenced by the magnetic flux and loss of the magnetic flux is decreased. Another object of the present invention is to provide an apparatus for producing metal powder which enables production of very clean metal powder to meet the demand for a higher quality. The above objects are achieved with an apparatus of the type mentioned in the beginning, which is characterized according to the present invention in that the nozzle part of the runner is a sliding gate made of a ceramics; that a ring-shaped magnetic flux-shielding plate made of an electroconductive and non-magnetic material is disposed between the second heating coil and the sliding gate; and that the flux-shielding plate is equipped with a cooling means. DRAWINGS Figs. 1 is a vertical section view showing the structure of the apparatus for producing metal powder of the present invention; Figs. 2 and 3 illustrate an example of the magentic flux-shielding plate used in the present apparatus, Fig. 2 being an axial section view, and Fig. 3, a plan view; Figs. 4 and 5 illustrate another example of the magnetic flux-shielding plate, Fig. 4 being an axial section view, and Fig. 5, a bottom view; Fig. 6 is to explain the shielding of the manetic flux in the present apparatus; and Fig. 7 is an enlarged vertical section view corresponding to the upper half of Fig. 1, which illustrates the holding vessel and the discharging runner of the preferred embodiment of the present apparatus. DETAILED EXPLANATION OF PREFERRED EMBODIMENTS The apparatus for producing metal powder of the present invention comprises, as illustrated in Fig. 1, a molten metal holding vessel 1 of bottomed cylinder shape, a molten metal discharging runner 2 installed at the bottom of the vessel, and a molten metal atomizing device 4 having gas-jetting nozzles 42 in a spraying chamber 41 connected to the lower end of the runner 2. The apparatus is provided with an induction heating coil 6 of a smaller diameter or a second heating coil 6 surrounding the discharging runner 2 in addition to an induction heating coil 5 of a larger diameter or a first heating coil 5 surrounding the vessel 1. The nozzle part of the discharging runner 2 is a sliding gate 22 made of a ceramics. A ring-shaped magnetic flux-shielding plate 7 made of an electroconductive and non-magnetic material is disposed between the induction heating coil 5 of smaller diameter and the sliding gate 22. The magnetic-flux shielding plate 7 is equipped with a cooling means. The gas-jetting nozzles 42 are of course connected to an inert gas source, and the spraying chamber 41 has a conveying means for the product powder 9, which are not illustrated. A preferred embodiment of the present apparatus for producing metal powder 9 uses, as the molten metal holding vessel 1, as shown in Fig. 7, a combination of a vessel body made by lining the inner wall of a shell 11 of a non-electroconductive and gas-impermeable material with refractory materials 12 and a lid 3 which can be gas tightly jointed to the body, and a vacuum generating means (not illustrated) is connected to the lid 3. Use of this molten metal holding vessel 1 enables production of very clean metal powder 9 with less contamination with air, particularly, oxygen. The magnetic flux-shielding plate 7 is made of electroconductive and non-magnetic material such as copper (or aluminum or non-magnetic stainless steel) in the form of a ring as illustrated in Fig. 3 and Fig. 5, and is disposed to surround the lower end of the discharging runner 2. Because the magnetic-flux shielding plate 7 is heated due to the induction current generated therein, it is necessary to provide a cooling means. One example of the magnetic flux-shielding plate 7A shown in Figs. 2 and 3 is a hollow body, and cooled by circulation of a cooling medium therein as shown with arrows in Fig. 3. The cooling medium may be air, but water is preferable. Another example of the magnetic flux-shielding plate 7B shown in Figs. 4 and 5 is of air-cooling type. This plate is preferably cooled by blowing air from the bottom with a fan (not illustrated). The sliding gate 22 made of ceramics can be opened and closed by synchronized advancing and backward movement of two pushrods 23 of oppositely installed hydraulic cylinders, i.e., by only pushing force in either direction. In the use of the molten metal holding vessel 1 shown in Fig. 7, if the sliding gate 22 is manipulated only by advancing movement of the pushrods, it is not necessary that the sliding gate 22 and the pushrods are connected, and the discharging runner 2 can be pulled out together with the vessel 1 from the first and second heating coils 5 and 6 when both the opposite pushrods are pulled back. Namely, it is possible to construct the vessel body and the lid 3 as portable type so that they may be handled separately from the other parts, the first and the second heating coils 5 and 6, the hydraulic cylinders and the means for atomizing molten metal 8. Connection between the lower end of the discharging runner 2 and the spraying chamber 41 can be made gastight by using a flexible joint 43 and a suitable sealing means. This apparatus for producing metal powder is operated as follows. At first, a molten metal 8 is charged in the holding vessel 1, while the sliding gate 22 is closed. The molten metal 8 may be prepared either in other melting apparatus or in this vessel 1 by placing the materials and melting them with the first heating coil 5. Then, in case of the preferred embodiment where the molten metal 8 is held under vacuum, while high frequency current is applied to the first heating coil 5 to keep the temperature of the molten metal, a lid 3 is placed on the vessel 1 and the space above the molten metal 8 is evacuated with a vacuum generating means (not illustrated). Evacuation prevents contamination with oxygen, and performs degassing to some extent. If necessary, it is possible to carry out supplemental refining by adding refining agents or adjustment of alloy composition. When the desired molten metal 8 is prepared under air or vacuum, the metal in the discharging runner 2, which was solid during the above operation, is heated to melt by applying current to the second heating coil 6, and the sliding gate 22 is opened. The molten metal 8 runs through the discharging runner 2 and flows down from the nozzle into the spraying chamber 41, where it is sprayed by jetting inert gas, typically, nitrogen or argon, to form the metal powder 9. The gas-atomizing can be practiced in accordance with the known technology. During the above discharging, the molten metal 8 in the discharging runner 2 is heated by magnetic flux Φ from the second heating coil 6, but, as shwon in Fig. 6, the magnetic flux-shielding plate 7 prevents extension of the magnetic flux Φ (Fig. 6) to the sliding gate 22, and thus, temperature increase of the sliding gate 22 and loss of the magnetic flux Φ by the sliding gate 22 is avoided. When the level of the molten metal 8 went down by progress of discharging, it is possible to keep the discharging rate by incressing the pressure in the space above the molten metal 8. In case of the operation under vacuum, extent of pressure reduction is decreased, for example, from 26.66·10³ Pa to 53.33·10³ PA (200 Torr to 400 Torr). This is preferable in view of obtaining a metal powder 9 of uniform quality. In the apparatus of the present invention, the metal 8 in the discharging runner 2 is heated by induction so that the metal may be discharged in the state of high fluidability. Due to the magnetic flux-shielding plate 7 disposed between the second heating coil 6 and the sliding gate 22, the magnetic flux Φ from the coil 6 does not extend to the sliding gate 22. Therefore, it is not necessary to consider the structure and the material of the sliding gate 22. Because the magnetic flux Φ does not reach the sliding gate 22, no loss of the magnetic flux Φ occurs at the sliding gate 22, and because the magnetic flux-shielding plate 7 is made of non-magnetic material, the loss of magnetic flux Φ in the flux-shielding plate 7 is very small. Thus, the present apparatus decreases loss of the magnetic flux Φ and satisfies the demand for energy-saving. Cooling of the magnetic flux-shielding plate 7 with a cooling medium makes it possible to form the magnetic-flux shielding plate 7 compact. In other words, the space occupied by the magnetic flux-shielding plate 7 between the second heating coil 6 and the sliding gate 22 is small, and substantially there is no space where the induction heating is not applicable due to the presence of the magnetic flux-shielding plate 7 at the lower part 21 of the discharging runner 2. Thus, discharging may not be prevented by solidification of the metal 8 in the discharging runner 2. At discharging the molten metal, decantation of the vessel is not necessary, and it is possible to discharge and interrupt discharging by application of high frequency current during a short period for induction heating and instantaneous gate opening/closing. The operation is much simplified and discharge from the bottom of the vessel makes the product free of slag contamination. In the case where the present apparatus of the preferred embodiment is used, the molten metal is held under vacuum or inert gas atmosphere, and, if desired, further refining such as degassing can be done, it is possible to prepare clean molten metal and discharge it while keeping under non-contaminating conditions. If the vessels are portable and plural vessels are prepared for exclusive use corresponding to a variety of steels, then the product powder is free from contamination by remaining steel, and maintenance of the apparatus is easier. EXAMPLE There was constructed an apparatus for producing metal powder of the type of holding the molten metal 8 under vacuum as shown in Fig. 7. With this apparatus, powder of SKH 51 was produced by nitrogen gas atomization. Oxygen content of the product powder was 20 ppm. This is a remarkable improvement when compared with the best product, which contains at least 80 ppm of oxygen, prepared by the operation under air.

Claims: An apparatus for producing metal powder comprising a molten metal holding vessel (1) of bottomed cylinder shape, a molten metal discharging runner (2) installed at the bottom of the vessel (1), a molten metal spraying device (4) having gas-jetting nozzles (42) in a spraying chamber (41) connected to the lower end of the runner (2) and a first and second heating coils (5, 6), the first having an induction heating coil (5) of relatively large diameter surrounding the vessel (1) and the second having a smaller diameter induction heating coil (6) surrounding the runner (2), characterized in that the nozzle part of the runner (2) is a sliding gate (22) made of a ceramics; that a ring-shaped magnetic flux-shielding plate (7, 7A, 7B) made of an electroconductive and non-magnetic material is disposed between the second heating coil (6) and the sliding gate (22); and that the flux-shielding plate (7, 7A, 7B) is equipped with a cooling means. An apparatus according to claim 1, characterized in that the molten metal holding vessel (1) comprises a body (12) made by lining refractory materials on the inner wall of a shell (11) of a non-electroconductive and gas-impermeable material and a lid (3) which can be gas tightly jointed to the body (12); and wherein a vacuum generating means is connected to the lid (3). An apparatus according to claim 1, characterized in that the magnetic shielding plate (7, 7A) is a hollow body and cooled by cooling water running therethrough.

Inventors: DEMUKAI NOBORU, FUJITA SENJI, DEMUKAI, NOBORU, FUJITA, SENJI
Applicants: DAIDO STEEL CO LTD, DAIDO TOKUSHUKO KABUSHIKI KAISHA
Application year: 1989
Main classification: B22F9
IPC codes: B22F9