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
New Trends of Metal Powder Manufacturing
Advanced Atomizing Process
- High Purity Atomizing Process
- High Pressure Water Atomizing Process
- New Design for Atomizing System
- Simulation of Atomizing Process
- Applications
Controlled Chemical Process
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
Advanced Atomizing Process
> 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
Advanced 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
Advanced Atomizing Process
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 ↓
Advanced Atomizing Process
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
Advanced Atomizing Process
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
Advanced Atomizing Process
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.
Advanced Atomizing Process
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
Advanced Atomizing Process
Powder Core
Reactor
Inductor
HEV Boost Inductor HEV LDC Inductor
Fe-Si-Al based
Fe-Ni based
Ni based
Applications : Magnetic Materials
Advanced Atomizing Process
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
Advanced Atomizing Process
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
Advanced Atomizing Process
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)
Advanced Atomizing Process
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)
Advanced Atomizing Process
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.
Advanced Atomizing Process
- Vapor Phase Process : IGC, PWE, Plasma
- Liquid Phase Process
: Reduction, Electroless plating, Sol-gel, Pyrolysis
- Solid Phase Process : MCP, SHS
- Applications
New Trends of Metal Powder Manufacturing
Advanced Atomizing Process
Controlled Chemical Process
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
Controlled Chemical Process
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
Controlled Chemical 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
Controlled Chemical 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
Liquid Phase Process
Controlled Chemical Process
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
Liquid Phase Process
Controlled Chemical Process
- Solvent evaporation : Spraying, Pyrolysis
- Microwave process
- Plasma Discharge Sphrodization
Liquid Phase Process
W-Re
Cu-Zr-Al
Pyrolysis system
Fe
Pyrolysis
PDS
Microwave
Controlled Chemical Process
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>
Controlled Chemical Process
매연정화 필터
Catalyst
(< 10nm)
Li-ion battery
Applications : Energy / Environment
PEMFC
Pd Au Pd-Pt Pd-Au
SOFC
Controlled Chemical Process
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
Controlled Chemical Process
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
Controlled Chemical Process
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
Controlled Chemical Process
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
Controlled Chemical Process
+ Polymer
Ceramic Fillers
High Density Sheet, Grease
Al2O3
BN AlN
Heat sink
TIM
Heat spreader
TIM
Substrate LED
Applications : Thermal Transfer
Controlled Chemical Process
Future Opportunities
?
?
Morphological
Control
Alloy or Hybrid
Nanostructures
Large-Scale
Synthesis
Catalytic & Device
Applications
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