Spherical powders enable new applications for metals

Free-flowing metal powders offer improvements for additive manufacturing, the production of targets for isotope production and much more.

Originally developed to optimize the manufacture of isotope production targets, the process, known as AMAZEMET rePowder ultrasonic metal sputtering, has wide-ranging applications for virtually all metallic elements and alloys.

The process is based on the ability to treat solid metals like liquids. This is achieved by creating uniform spherical particles that behave like tiny ball bearings. The method works by splitting irregular pieces of metal into tiny droplets through vibration. These droplets are then fed into a chamber containing inert gas, where they are transformed into spherical particles by surface tension and rapidly cooled. These free-flowing metal powders can then be pumped or transported through gases in a similar way to liquids.

The ability to turn almost any metallic element or alloy into a spherical powder that can flow opens up new perspectives for additive manufacturing. These powders can be fused into complex shapes that would be difficult to produce using conventional methods. For example, they could be used in the nuclear industry to manufacture targets for isotope production, but also for the production of high-performance batteries or special filters.

The AMAZEMET rePowder process uses a water-cooled platform that vibrates 20,000 times per second to break up a metal melted on the platform into droplets. These are melted by an electric arc process and rapidly cooled in an argon environment. A sieve at the end of the process allows the particles to be separated according to size.

While the sphericity of metal powders is not new, the ability to produce small quantities of almost any element in a flowable form represents a significant advance. Until now, such powders were mainly available in large batches and for specific alloys such as stainless steel or titanium. The development of rePowder aims to harness rare and unusual materials for additive manufacturing and open up new applications beyond isotope production.

This process could open the door to new applications in 3D printing technology and offers potential for a variety of industries that benefit from the ability to convert metals into flowable powders.