The Recent Development in Metal Powder Technology

2011. 10. 31.

Changsung corporation

The Recent Development in

Metal Powder Technology

In-Bum Jeong

Core, Inductor

DC, AC Reactor

Magnetics Thermal Electronics EMI/EMC

P/M Parts

Tools, Brazing

P / M

Conductive fillers

Electrical contacts

Heat sink, TIM

Heat spreader

EMI absorber

Shielding Material

Machine part

Electric contact Magnetics

Filter

Paste Welding

Tool Propulsion

Spray coating

Friction

Filler

Battery

Reductant

Abrasive Heavy alloy

Substitution Material

Drug transfer

Bio / Medical Information Environment Energy Culture

Fuel cell parts

Catalyst

Diesel Particulate Filter

Catalyst, Sensors

E-ink book

Smart card, RFID

Digital media parts

Architecture Projection

Applications of Metal Powders

Core

Fe-Si-Al Fe-Ni

PM part

W-Cu

Cu alloy

TIM

BN

AlN

Smart phone & Metal powders

Touch screen Ag Flaky Ag

Ag-Cu

Shielding Material

Ni

EMI absorber Fe-Si-Al

RFID Flaky Ag Ag

Chip device

Ag Cu Ni Pd-Ag

Battery Pd-Pt Au

Notebook PC & Metal powders

Chip device

Ag Cu Ni Pd-Ag

Touch screen

Ag Flaky Ag

TIM

BN

AlN

EMI absorber

Fe-Si-Al

Ag-Cu Ni

Shielding Material

Ag Flaky Ag

Membrane touch switch

Shielding Material

Flaky Ag Core

Fe-Si-Al Fe-Ni

Cu-Zn Cu Cu-Fe

HDD Bearing

Battery

Pd-Pt Au

Atomized Cu

Reduction Ag

Physical : Atomizing

Mechanical : Milling

Chemical : Reduction, Pyrolysis

Electrical : Decomposition

Flaky Ag

Electrolytic Cu

Metal Powder Manufacturing Process

Information

Nano

Biology

Powder Technology Revolution

Nano-sized / Nano-crystal Powder

Composite Powder

High purity Powder

Innovation by convergence technologies !!

Improvements and new features of the metal powder material properties

New Trends of Metal Powder Manufacturing

Advanced Atomizing Process

- Vapor, Liquid, Solid Phase Chemical Process

- High Purity Atomizing Process

- High Pressure Water Atomizing Process

Controlled Chemical Process



- High Purity Atomizing Process

- High Pressure Water Atomizing Process

- New Design for Atomizing System

- Simulation of Atomizing Process

- Applications


High Temperature (＞ 1600℃)

Manufacturing of multi-components alloy powders,

high purity powder by purity system in vaccum

High Purity Atomizing Process

Ni- alloy

- Shape : Spherical

- Size(D50) : 25um

- TD(g/cc) : 5.5

- O2 Cont. : ＜ 200ppm

(Ni, W, Mo, Cr, Co, Ti, Al, B)

High Bypass Jet Engine


＞ 1000kgf/cm2

Low pressure : 300kgf/cm2

- Shape : Irregular

- Size(D50) : 30um

- TD(g/cc) : 3.0

Cu powder

Cu powder

High pressure : 1000kgf/cm2

- Shape : Spherical

- Size(D50) : 1.5um

- TD(g/cc) : 4.5

High Pressure (＞ 1000kgf/cm2)

: High energy – extremely fine spherical powder manufacturing (＜ 3㎛)

High Pressure Water Atomizing Process


Fe-Ni-Si alloy

Axisymmetry Non- Axisymmetry

The latest designed shape of atomizer

Subsonic

(Convergent Nozzle)

Supersonic

(Convergent-Divergent Nozzle)

New Atomizer Design

De Labal tube

(Convergent-Divergent Nozzle)

Velocity (V) : ↑

Temperature (T) : ↓

Pressure (P) : ↓

New Design for Atomizing System


173 mm2 342 mm2 536 mm2

0 mm 3 mm 5 mm

Water Atomizing

Movement of gas according to change of air gap

Movement of gas according to the length of nozzle

Establishment of optimum conditions estimating thermal / dynamic

change in accordance with atomization conditions.

Simulation of Atomizing Process

Gas velocity ↓


1. Metal Foam Coil

2. Binder Solution Spray

3. Alloy Powder Application

4. Cut into sheets

5. Heat Treatment (De-binding & Sintering)

6. Alloy Metal Foam

Silencer for Cars

Exhaust Filter for Various Diesel Engine

Industrial & Vehicle Exhaust Gas Treatment

Fe-Cr-Al-Ni based Fe-Cr-Al based

Applications : Metal Foaming


Cu powder Fe-Cr-Ni based

Applications : Metal Injection Molding

Mobile phone Industrial part Ammuniton/Automobile

Powder Metallurgy

Plastic Injection Molding

Metal Injection Molding (MIM)

Precision high accuracy parts manufacture without internal defect

Low oxygen content, fine spherical particle is require

(O2 content : ＜ 3000ppm, shape : spherical, size : ＜ 20㎛)

ex) Fe-Cr-Ni based, W-Ni based, Pure Cu powder etc.

Application

- Telecommunication

- Computer & digital media

- Electric/electronic

- Automobile

- War industry

- Medical


Ni-Cr based

Applications : Thermal Spraying

- Hard-facing of automobile (Ni based, Co based alloyed powder)

: Wear, impact, erosion resistance, high-temperature strength

- Melting Range : 1250~1400 ℃

- Particle shape : spherical

- Size(D50) : 60um

Coating processes in which melted materials are sprayed onto the substrate

and involve the rapid heating and cooling.

Coating materials : various metals, ceramics and composites.


Schematic cold spray process

Ti-Cr based

- Shape : Variable

- Size(D50) : < 50um

- TD(g/cc) : 5.0

Applications : Cold Spraying

The solid powders accelerated in supersonic gas jets impact with the

substrate, plastic deformation of particles and adhere to the surface.

Electronic / aerospace

Application

- Automobile, aerospace

- Medical & biomaterial

- Oil & gas industry

- Waterpower generation /

fuel cell electrode material

Kinetic energy of the particles Plastic deformation energy during bonding


Powder Core

Reactor

Inductor

HEV Boost Inductor HEV LDC Inductor

Fe-Si-Al based

Fe-Ni based

Ni based

Applications : Magnetic Materials


Cooling Fan Motor

Front Wiper Motor

Power Window Motor

Starter Motor

Battery Link

A.D (g/cc) F.R (sec/50g) Strength (kg/m2)

Pre-alloyed < 2.3 40 Max 1.46

Pre-mixed 3.0~3.3 45 Max 0.68

Applications : Oil Impregnated Bearing

<Pre-alloyed> <Pre-mixed>

Bronze

Applications

- Automobiles

- Electric Home / Office Appliances

Pre-alloyed bronze powders of Sponge-form

: Low density, flowability, formability , sinterability


Laptop Heat Pipe System Heat Pipes

Cu Metafoam enhances

heat pipe capillary force

Principle of Heat

Heat pipe : CPU

Cu powder

Cu powder

(150㎛, +140mesh ∼ -80mesh)

Applications : Heat pipe

Applications

- Artificial satellite

- Heat exchanger

- Electric/electronic

- Airstrip/road

- Auto industry


Matrix-Filler Metal Combination

Welding

Brazing

Brazing Blade Ceramic heater (Metallized)

Ni-Cr-P based

Heat exchanger

Applications : Brazing

Advantages of brazing

- Complexed shape

- Low thermal distortion

- Multi-parts assemblies

- Clean joint (without finishing)


Anatomic plate

Screw

Grip (trochanter)

Cable

Neuro Flap

Total Knee system

Applications of Bio-metal

Artificial hip joint

Applications : Biomedical

Ti Co-Cr-Mo

Ti-Al-V Ni-Ti

High strength and formability characteristics are applied to bone and joint

replacement

Ex) SUS316L, CoCrMo, Ti6Al4V, Nitinol(Ni-Ti)

Nitinol (shape emory alloy)


Ceramic substrate

Bi-Te-Sb-Se Powder

Thermoelectric

Applications : Thermoelectric

A typical thermoelectric module is composed of two ceramic substrates

(P-type and N-type elements)

Conventional method Development in progress

Ingot module Powder metallurgy

Developments in thermoelectric metal powder by atomization process

Peltier effect

: A temperature difference created by applying

a voltage between two electrodes connected to

semiconductor material.


- Vapor Phase Process : IGC, PWE, Plasma

- Liquid Phase Process

: Reduction, Electroless plating, Sol-gel, Pyrolysis

- Solid Phase Process : MCP, SHS

- Applications




1) Inert Gas Condensation : IGC

2) Pulsed Wire Evaporation : PWE

3) Enhanced Plasma Discharge Process

4) Aerosol

- Vapor-reduction synthesis

- Chemical Vapor Condensation : CVC

- SFE, Plasma Quench Process

Vapor Phase Process

Vapor phase process of producing a powder by evaporating material (ingot,

precursor) into high energy such as plasma.

- Control the size of a particle by changing of energy source

- Can be applied to any metal powders

- Oxide, nitride, carbide can be produced by controlling atmosphere

Transfer gas

Inert gas (He, Ar, Xe, Ne)

Activated gas (O2, CH4, C6H6)

Control factors : size, structure

Collision probability

Vaccum pressure

Power source


The high energy power (heating, current pulse, laser) is passed

through a metallic materials (ingots, salts, wires)

Metallic sources are vaporized

The supercooled metal vapors condensed and formed powders

SI – C –N (100nm)

Ni (200nm) Fe (100nm)

Ni-Cr (10nm) Pulsed Wire Evaporation

Vapor Phase Process

Inert Gas Condensation, Pulsed Wire Evaporation Controlled Chemical Process

Enhanced Plasma Discharge Process

Plasma Metallurgy : RF thermal Plasma for spraying and powder production

- Typical values for the plasmas used in materials processing

ne 1016 - 1018 m-3 , Te 104 - 105 K (1 - 10 eV)

- Industrial Scale Production of Nanopowders by thermal plasma using the ICP

(Inductively Coupled Plasma Technology)

RF Plasma

Powder

Ag powder (90nm)

Cu powder (70nm)

Ni powder (22nm)

Co powder (20nm)

Vapor Phase Process


A wet-chemical technique widely used recently in the fields of materials

science and engineering.

Pd-Au Bimetallic Pd-Pt Core-Shell Pd-Pt Nanodendrites Pd-Pt NanoAlloy

Polyol Synthesis : Changes of nanostructure

Nanocubes Nanobars Octahedral

Easily controlled shape of nanostructure

Chemical Reduction Process

Liquid Phase Process


Thermal method Synthesis (Autoclave) : Nano silver wire

Flexible electronics: Display & organic solar cell

growth approach Nano-wire

Precipitation Synthesis : Silver plate

PVP-Mediated Synthesis : Nano-Ink

Au nano-ink Ag nano-ink

Capping agent : Shape control

Reductant : Size control Ag plate



Ni

Ag/Ni Au/Ag/Ni

Ni

Ag

Au

A chemical reduction process which depends upon the catalytic reduction

process of metal ions in an aqueous solution

● Uniformity of the deposits,

even on complex shapes

● Various core/shell materials

(Core : metal, ceramic, polymer…)

● Electroless metal / polymer composite

Ag/Cu Ag/Ni Au/Ni Cu/Fe

Ni Ag/Ni Au/Ag/Ni

Ag Au

Electroless Plating Process



- Solvent evaporation : Spraying, Pyrolysis

- Microwave process

- Plasma Discharge Sphrodization


W-Re

Cu-Zr-Al

Pyrolysis system

Fe

Pyrolysis

PDS

Microwave


Self-propagating High-temperature Synthesis (SHS)

: Producing composite from elemental material in a short time with only igniting energy

Solid Phase Process

Solid phase process is a method of producing intermetallic, carbide, nitride

compound powder from metallic salts and reducing gases.

Ex) NiAl, TiAl, TiC, SiC, VC, Si3N4…

Mechanochemical process (MCP)

: The mechanical and chemical phenomena on a molecular scale

SHS (combustion wave)

Ni-BaTiO3 composite BN

<MCP> <SHS>


매연정화 필터

Catalyst

(＜ 10nm)

Li-ion battery

Applications : Energy / Environment

PEMFC

Pd Au Pd-Pt Pd-Au

SOFC


RFID Tag

E-ink display

Touch screen Photovoltaic cell

Pressure sensor

Primary battery

Smart card

Thermoelectronics

Nano - Ink

Applications : Printed Electronics

Ag Cu Au

Powder size : 50 – 200nm


Magnetic Nano-bacteria

Drug transfer system Cell perception system

Pt/Den-NH2-CD-NT Ag/Den-COOH-CD-NT

Applications : Biomedical

Nanoparticle research is currently an area of intense scientific interest due

to a wide variety of potential applications in life science, biomedical field


Milling

Process Flaky Powder

Applications : EMI / EMC

Fe-Ni based

Electromagnetic Spectrum (3kHz – 300GHz)

3kHz 30kHz 300kHz 3MHz 30MHz 300MHz 3GHz 30GHz 300GHz

Navigation Ship Short wave FM Satellite

EHF SHF UHF VHF HF MF LF VLF

Microwave

Mobile Phone Rader Milliwave


W-Cu heat sink for LED device

- Comparability for CTE of substrates

- High thermal conductivity

- High density

Cu heat sink for CPU

Mat. CTE

ppm/o C

T/C

(W/K•m)

Heat

Sink

Al 25 177

Cu 17 403

Ga 6 46

W-Cu 8 200

Subst.

Al2O3 7.6

- BeO 8.0

AlN 5.8

GaAs 6.2

Thermal coefficient and conductivity

Structure of radiation heat for LED

Heat Sink

Cu-W(Complex) Cu-W(coating) W

Applications : Thermal Transfer


+ Polymer

Ceramic Fillers

High Density Sheet, Grease

Al2O3

BN AlN

Heat sink

TIM

Heat spreader

TIM

Substrate LED

Applications : Thermal Transfer


Future Opportunities

?

?

Morphological

Control

Alloy or Hybrid

Nanostructures

Large-Scale

Synthesis

Catalytic & Device

Applications

www.changsung.com

Thank you !!

The Recent Development in Metal Powder Technology

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