HOME POWDER PRODUCTION EQUIPMENT INNOVATION R+D TECHNICAL NEWS CONTACT CAREERS EMPLOYEES Atomising Systems Latest News ASL SUPPLY 250kg VACUUM INDUCTION MELTING ATOMISER TO LIBERTY POWDER METALS IN PARTNERSHIP WITH CONSARC Posted 10/2021 Atomising Systems Ltd. (ASL), the Sheffield based metal powder atomising specialists, and Consarc Engineering (Scotland) have delivered and commissioned a Vacuum Induction Melting Gas Atomiser (VIGA) for Liberty Powder Metals Ltd. (LPM) site in Teesside, England. The 250kg atomiser takes advantage of ASL’s Anti-Satellite technology, producing highly spherical powders giving optimum flow properties. This, coupled with Consarc’s renowned vacuum melting technologies, will now allow Liberty to supply powders to their existing specialist clients in the aerospace and high specification metal businesses, as well as opening up new opportunities, primarily in the AM field. Both nickel-based superalloy and stainless steels were successfully produced during start-up. ASL and Consarc’s UK-based staff were able to install and commission the plant working within the restrictions imposed by the Covid-19 pandemic. Such restrictions meant that things were not quite as easy to complete as in pre-Covid times. The fact that ASL operates its own in-house Anti-Satellite gas atomisers on a daily basis (3 shift) was very useful for LPM, as their staff were able to obtain real world experience of production-scale gas atomiser operation prior to the installation and commissioning of their VIGA, allowing them a clearer understanding of the tasks involved and the subtle issues of handling metal powders. Photograph: Courtesy Liberty Powder Metals Ltd. ASL COMPLETE REMOTE COMMISSIONING OF PLASMATEC'S ATOMISER DURING PANDEMIC Posted 07/2021 Atomising Systems Ltd. (ASL), the Sheffield based metal powder atomising specialists, have successfully commissioned a water atomiser for PrJSC PlasmaTec, the leading producer of welding consumables in the Ukraine. As the Covid-19 pandemic meant it was impossible to send any staff to site, remote working was the only option. This allowed steady progress to be made despite time-zone and language differences. This involved the extensive use of WhatsApp for discussions involving two largely home-working ASL staff, an interpreter, and the client’s plant manager. Zoom and PowerPoint were used for training the operating crew remotely (again through an interpreter) and an internet-linked camera allowing ASL staff to view the atomiser from home or office, The plant, like most systems supplied recently by ASL, is controlled by a PC/PLC system and the ASL control engineer was able to view the system status and operating logs for all parameters while communicating with his opposite number within the system using Google translate. So, while installation began in early 2020 and the final installation and start-up were badly delayed by the pandemic and by local Covid restrictions, the process overall went quite smoothly, and the client is very happy with the plant’s operation and the product’s quality. The plant’s water atomiser, mated to the client’s 600kg capacity furnace, is now routinely achieving tap-to-tap times below 2 hours. The plant process both steel and ferroalloy powders. Compared with pre-pandemic practice, the process of start-up was far less stressful for the commissioning engineers, who normally are under severe time pressure and working very long hours on site, due to the need to keep site weeks to a minimum. With remote commissioning, it is possible to take a more relaxed attitude to time, whilst teething issues with equipment interfaces are sorted. It also meant that the excellent communications allowed sharing of information over a much longer time, extending into shake-down and ramping up production, than is feasible with a short site engineer’s visit. With this excellent experience, it is very likely that ASL will consider a hybrid site/remote commissioning strategy for future projects to combine the best points of both options. ASL INVESTS IN NEW LABORATORY FACILITIES FOR RAPID POWDER ANALYSIS Posted 03/2021 Atomising Systems Ltd. has invested £150,000 to upgrade its in-house chemical analysis facilities with the addition of an ICP-OES system. This expands the range of elements that can be reliably analysed in-house to cover almost all alloys in regular production, such as stainless steels, nickel and copper alloys, for Additive Manufacturing, MIM, Press and Sinter, Brazing, Thermal Spraying etc. To house the new equipment, some of which involves the use of very aggressive acids to bring such corrosion-resistant alloys into solution, a new specially ventilated laboratory has been constructed, meaning ASL now has three laboratories for different types of powder testing. Current staff have been trained and the equipment is now performing well. Extra staff will also be hired as demand increases. This facility now means that ASL’s laboratories can now test: Chemical composition via ICP-OES and XRF Powder oxygen, nitrogen, carbon, and sulphur by Eltra systems Particle size by laser diffraction and sieving Particle shape by Hall and Carney funnels, density cup, Tap Density, Optical Microscopy Compressibility and Green Strength Quality Manager, Dan Lodge, is delighted to improve the capability of the quality department. “We now measure our laboratory turn-round time in hours, while external analysis can take up to a week. Rapid results from the new equipment will allow our Production department to be much more responsive and will also support our extensive R&D projects.” Managing Director Simon Dunkley said, “We are pleased with this major investment; this is the first step in our current expansion plans which by 2022 will see a 50% increase in capacity enabling more efficient production of high-grade powders for our increasingly demanding customers in Europe and the USA.” ASL COMMISSIONED AN ADDITIONAL 400kg BATCH AM & MIM GAS ATOMISER AND NOW ADDS ADDITIONAL MELT CAPACITY Posted 01/2020 Atomising Systems Ltd. (ASL), the Sheffield based metal powder production company, recently expanded its capacity through the installation of a new 400kg gas atomiser aimed specifically at the AM and MIM powder markets. An additional melter is now being installed for greater flexibility and capacity. The in-house designed atomiser, equipped with ASL’s proprietary Anti-Satellite and Hot Gas system, produces high yields of MIM and or AM powders, enabling ASL to continue to serve its ever expanding AM and MIM customer base. ASL is a specialist in the production of stainless steel powders, although its production expertise does not stop there, with a considerable number of low alloy and Ni based alloys in the portfolio. “The addition of another atomiser, along with the associated sieving and classification equipment means that we are able to keep pace with the growth of our existing client base and the requirements of new clients, especially in the AM and MIM sectors. “In these sectors, the benefits of ASL’s Anti-Satellite technology are clearly recognised through the excellent powder shape and flow properties”, said Commercial Director, Paul Rose Thanks to ASL‘s Anti-Satellite technology, ASL powders are low in satellite and high in flowability. BUILDING FOR THE FUTURE Posted 11/2019 Contact Details: Dan Lodge, Quality Manager Atomising Systems Ltd 371 Coleford Road Sheffield S9 5NF Tel: 0114 2626200 Email: info@atomising.co.uk Website: www.atomising.co.uk Atomising Systems Limited, the Sheffield-based powder metallurgy company, continues to recognise the importance of workplace apprenticeships. The Company has been fortunate to take on and witness the development of fourteen young people since first recruiting apprentices in 2009. ASL is pleased to report that a further five apprentices have joined the Company this year. Two of the new apprentices are working with ASL’s maintenance team. Both are busy learning their trade with the Works Maintenance Engineer and the Works Electrician, focussing on the upkeep of ASL’s highly sophiscated atomisation and metal powder processing equipment The remaining three new recruits have joined the ASL laboratory where they are learning the complex analytical requirements of metal powders for quality assurance, production support, and research and development purposes. They are working alongside two former apprentices who recently graduated from their studies to become qualified Laboratory Technicians under the quidance of a former apprentice who was appointed to the role of Quality Control Manager earlier this year. ASL has also been working with UTC Sheffield to offer work experience placements for A-level students who are interested in engineering and material sciences. Dan Lodge, Quality Manager, said: “ASL has been committed to the training and development of young people for many years and we intend to continue offering these opportunities in the future. The recruitment of new apprentices is an investment in their future and in the future of the business. Orders for our metal powders have increased in volume, range and complexity, particularly following the installation of an additional gas atomisation production line.” The new starters are currently on a comprehensive induction course taking in all of ASL's production sections. All five apprentices attend college on a regular basis and we are hoping that after two years they will be qualified and able to move on to full technician status with excellent knowledge of ASL’s specialised industrial processes. ATOMISATION FOR METAL POWDERS COURSE MANCHESTER 2020 Posted 9/2019 Atomising Systems Ltd and Personal Development Advanced Courses (PERDAC), a division of CPFResearch Ltd, will hold their popular short course on atomisation for metal powders in 2020. The two-day course will take place from March 5-6 in Manchester, UK. The course will consist of presentations from John Dunkley (Chairman, Atomising Systems Ltd), Dirk Aderhold (Technical Director, Atomising Systems Ltd), Rajeev Dattani (Applications Specialist, Freeman Technology) and Andrew Yule (Emeritus Professor, Manchester University). Developed for engineers working in metal powder production and/or R&D, the programme combines up-to-date practical information with theory. On the agenda are all current atomiser types and uses, key instrumentation, essential theory and computer modelling, and plant design, operation and economics. https://www.cpfresearch.com/courses/amp-course/ LIBERTY SPECIAL STEELS ORDER 250kg VACUUM INERT ATOMISER Atomising Systems Ltd. (ASL) of Sheffield, England, has been awarded a contract for the turnkey installation of a 250kg Vacuum Inert Gas Atomiser by Liberty Powder Metals Ltd. Working in co-operation with Consarc Engineering the Vacuum Melting technology suppliers, ASL has equipped the atomiser with its proprietary Anti-Satellite and hot gas atomisation systems. The high specification atomiser will enable Liberty to produce highly spherical, extremely free flowing, special steel-based and non-ferrous alloy powders for their demanding aerospace clients to use in additive manufacturing. ASL Commercial Director, Paul Rose, “The Anti-Satellite technology is a game changer in terms of powder shape and flow properties. Coupled to a vacuum melting furnace from a renowned specialist like Consarc, Liberty will be set to supply their clients with powder of the highest quality” ATOMISATION FOR METAL POWDERS COURSE MANCHESTER 2019 Atomising Systems Ltd and Personal Development Advanced Courses (PERDAC), a division of CPFResearch Ltd, will hold their popular short course on atomisation for metal powders in 2019. The two-day course will take place from March 14-15 in Manchester, UK. The course will consist of presentations from John Dunkley (Chairman, Atomising Systems Ltd), Dirk Aderhold (Technical Director, Atomising Systems Ltd), Tom Williamson (Research Engineer, Atomising Systems Ltd), Rajeev Dattani (Applications Specialist, Freeman Technology) and Andrew Yule (Emeritus Professor, Manchester University). Developed for engineers working in metal powder production and/or R&D, the programme combines up-to-date practical information with theory. On the agenda are all current atomiser types and uses, key instrumentation, essential theory and computer modelling, and plant design, operation and economics. https://www.cpfresearch.com/courses/amp-course/ STEWARD ADVANCED MATERIALS APPOINTED USA AND AMERICAS DISTRIBUTOR FOR ASL POWDERS Sheffield company Atomising Systems Ltd. has appointed Steward Advanced Materials LLC (SAM) to represent and distribute ASL's gas and water atomised powders Steward Advanced Materials LLC. was founded in 2002 as a division of Steward, Inc. who have been family-owned for 130 years. They provide highly engineered specialty metallic and ceramic materials for global energy, industrial and consumer markets making them an ideal partner for ASL and our powder portfolio of stainless steel and alloyed powders. SAM are based in Chattanooga TN with contact details: https://www.stewardmaterials.com/products/atomized-powders/ EUROPM2018 CONGRESS AND EXHIBITION 14-18TH OCTOBER BILBAO, SPAIN ASL will be exhibiting at the European PM Exhibition on booth 169 https://www.europm2018.com/ WORLDPM2018 CONGRESS AND EXHIBITION 17-19TH SEPTEMBER BEIJING, CHINA ASL will be present at the WorldPM2018 exhibition. Visit us at booth No. A222 ATOMISATION FOR METAL POWDERS COURSE MANCHESTER 2018 Atomising Systems Ltd and Personal Development Advanced Courses (PERDAC), a division of CPFResearch Ltd, will hold their popular short course on atomisation for metal powders for the eleventh time in 2018. The two-day course will take place from March 8-9 in Manchester, UK. The course will consist of presentations from John Dunkley (Chairman, Atomising Systems Ltd), Dirk Aderhold (Technical Director, Atomising Systems Ltd), Tom Williamson (Research Engineer, Atomising Systems Ltd), Doug Millington Smith (Principal Applications Specialist, Freeman Technology) and Andrew Yule (Emeritus Professor, Manchester University). Developed for engineers working in metal powder production and/or R&D, the programme combines up-to-date practical information with theory. On the agenda are all current atomiser types and uses, key instrumentation, essential theory and computer modelling, and plant design, operation and economics. http://www.cpfresearch.com/courses/amp-course LABORATORY APPRENTICES AT ATOMISING SYSTEMS We have appointed two new apprentice technicians in the Laboratory due to significant increases in the order levels for metal powder. With orders stretching way into 2018 and staff numbers at over 70, further plans are to construct an additional facility at the company's Darnall premises. The new apprentices are joining the busy ASL laboratory where two of their colleagues have recently graduated from their own apprenticeships. The new starters are currently on a comprehensive induction course taking in all of ASL's production sections. As part of a programme of continuous improvement, the laboratory has recently been extensively remodelled and expanded, both in size and with new equipment, to meet the increasing demands of ASL's growing customer base. Dan Lodge - ASL's Quality Manager - says; "Being able to process samples through the laboratory efficiently and effectively is essential to ensuring the timely delivery of our high quality metal powders. Our former apprentices have set the bar high with their capability and critical attention to detail and I am convinced that our new team members will meet these excellent high standards." EUROPM2017 CONGRESS AND EXHIBITION 1-4TH OCTOBER MILAN, ITALY ASL will be exhibiting at the European PM Exhibition on Stand No. 31 PM CHINA 2017 26-28TH APRIL SHANGHAI, CHINA ASL will be exhibiting at the PM show in Shanghai on stand B272. We look forward to seeing you in Shanghai. WORLDPM2016 CONGRESS AND EXHIBITION 9-13TH OCTOBER HAMBURG, GERMANY ASL will be present at the WorldPM2016 exhibition. Visit us at booth No. 164 For more details please see www.worldpm2016.com 2017 ATOMISING COURSE IN MANCHESTER The atomising course will again be run in Manchester, England, on the 23rd - 24th February 2017. www.cpfresearch.com/courses/amp-course ASL FOUNDER RECEIVES MEDAL MON 18 JULY Dr John Dunkley, the founder of Atomising Systems Limited, recently received the prestigious Ivor Jenkins Medal from the Institute of Material Minerals and Mining in London. The medal recognises his significant contribution to the scientific, industrial and technological understanding of materials processing using particulate materials. John greeted the award with the words, “I am delighted to have been chosen to receive this medal; it is very rewarding to have the approbation of colleagues whom you have worked with during a long career,” John has spent over 40 years working on the atomisation of molten metals to make metal powders, and founded Atomising Systems Ltd of Darnall, Sheffield, in 1992. ASL now employs over 60 staff and produces thousands of tons/year of metal powder. As well as publishing over 30 papers and a book on atomisation, John edited the scientific journal, Powder Metallurgy, for 10 years. ASL is now run by John’s son, Simon Dunkley, but John continues to work to help with the growth of the company in a technical role. “Problem-solving is what gets me out of bed in the mornings” he says. Attached photo: JJD receiving medal from Mike Hicks, President of the Institute and former Global Head of Materials Engineering at Rolls-Royce. PM CHINA 2016 27-29TH APRIL SHANGHAI, CHINA TUE 15 MARCH ASL will be exhibiting at the PM show in Shanghai. See us on booth A222. ULTRAFINE GAS ATOMISED POWDERS AVAILABLE FROM ATOMISING SYSTEMS ASL'S IMPROVED GAS ATOMISER AND EXPANSION FOR QC LABORATORY MON 14 MARCH ASL has undertaken significant R&D work on its gas atomiser to address the increasing market for ultrafine gas atomised powders. Following the development of a greatly improved tundish system, the 200kg batch capacity gas atomiser has now been upgraded with a high power gas heater allowing much higher atomising gas temperatures to be achieved. This, coupled with extensive work on ASL's gas atomising nozzle system enables the production of stainless steels with median particle size of less than 20 microns. Further investment in uprated sieving and classification systems, allows ASL to undertake powder separations from over 100microns down to less than 5 microns. With these upgrades ASL has increased its production capacity for the finest grades more than twofold. The QC laboratory has received a significant expansion with a new Malvern Mastersizer, a total oxygen determination instrument, a compaction press and tensometer for green determination of water atomised powders, and an XRF chemical analyser. All are now in operation, assuring the quality and consistency of the Ultrafine gas atomised powders. This QC laboratory investment of well over £200,000, coupled with the recruitment of extra laboratory staff, ensures ASL can provide a QC service exceeding that expected of our demanding clients. Simon Dunkley, ASL's Managing Director says; "While a massive increase in orders for water atomised powders has kept us very busy, we have not neglected to develop our capability to serve our gas atomised powder clients with new grades for MIM, AM , HIP and thermal spray processes amongst others. These investments are already proving to be extremely beneficial." EURO PM2015 CONGRESS AND EXHIBITION 5-7TH OCTOBER REIMS, FRANCE ASL will again be present at the ever popular Euro PM exhibition. Visit us at booth No. 82. MAJOR EXPANSION OF ATOMISING SYSTEMS Sheffield company Atomising Systems Ltd. reports that it has dramatically expanded its workforce to cope with a major influx of orders for metal powder. Staff numbers at their Darnall facility have increased from 35 in September 2014 to over 60 in June to allow ASL’s two 500kW melting furnaces to operate at maximum output to service an order book stretching into 2016. Four new apprentices have been taken on to join several that were hired two years ago and who are now finishing their training and making a major contribution to the workforce. Before they start their college day-release courses in autumn, they will be working in production, quality control and maintenance to see which areas are of most interest to them. As well as hiring enough staff to operate the existing plant at maximum output, ASL is investing heavily in new equipment. A £100k major upgrade of the gas atomiser is in hand, while a large new sieving station of similar cost has just been put into production on special steel grades. In addition a new £25k instrument using laser diffraction to measure particle sizes as fine as one micron has been purchased and the QC laboratory is being expanded with the addition of a £30k oxygen analysing instrument. As a family-owned company, ASL has always invested all its profits into equipment and R&D projects in order to continually grow the business. Simon Dunkley, who took over management of the company from his father, Dr John Dunkley, in 2010 says; “After some tough times, it is very gratifying to see our investment in plant and research at last paying dividends. It is particularly pleasing to be able to offer so many young people the opportunity to work in a leading-edge technical environment that allows so much scope for them to develop their talents. Our recent investments should further allow us to fulfil the exacting demands of leading metal powder users around the world.” ATOMISING SYSTEMS LTD: MAKING THE EQUIPMENT THAT MAKES THE POWDER FOR OVER 20 YEARS Atomising Systems Ltd builds and installs metal atomisers throughout the world for a wide range of applications as well as manufacturing a range of specialist metal powders. Dr David Whittaker reports on a visit to the company. Read full Article (Pages 39–43) HOME POWDER PRODUCTION EQUIPMENT INNOVATION R+D TECHNICAL NEWS CONTACT CAREERS EMPLOYEES Atomising Systems Ltd., 371 Coleford Road, Sheffield, S9 5NF, England Tel +44 114 2626200. Fax +44 114 2626201 . info@atomising.co.uk Company No 2731401 Incorporated in England VAT No GB 600 1033 29 GPDR Statment FM 581102 EMS 673187