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Ultrasonic metal atomization

ATO Technology uses ultrasonic vibrations to break a molten metal into small droplets that quickly solidify into metal powder under an inert gas protective atmosphere. The size of the metal powder produced is affected by the ultrasonic frequency used, with higher frequencies producing smaller particles and lower frequencies producing larger particles. Other factors that affect particle size and distribution include viscosity, density, ultrasonic amplitude and atomizer design.
The process of ultrasonic atomization of metal powder using the atomizer with ATO technology involves feeding raw material into the pressurized atomization chamber where an electric arc is created to melt the material. Ultrasonic vibrations are transmitted through a sonotrode to the molten metal bath, forming capillary waves that eject metal droplets with a diameter that depends on the ultrasonic frequency, surface tension, and density of the liquid metal. The droplets are ejected into a cooled stream of argon gas and rounded into near-perfect spheres by surface tension. The droplets then cool and solidify before being sorted and collected.

Our ultrasonic metal powder atomizers

Lab Plus

reactive and
non-reactive metals
low waste
open atomization
parameters

ATO Lab Plus is an innovative device designed to produce high-quality metal powders for additive manufacturing applications. This atomizer is capable of producing a wide range of both reactive and non-reactive metal powders, including aluminum, copper, stainless steel, titanium, and other alloys. This makes it an incredibly versatile tool that can be used in a variety of applications across multiple industries.
In terms of usability, the ATO Lab Plus features an intuitive control system with a user-friendly interface, along with the precise control over parameters. Operators can easily adjust parameters to achieve optimal powder properties for their specific needs. This ease of use makes the ATO Lab Plus an ideal tool for research and development as well as industrial-scale production. The system is also equipped with a number of safety features, including a cooling water monitoring system, automatic gas shut-off valves, and emergency stop buttons.

Noble

precious metals
maximum material
recovery
parameters dedicated
under precious metals

ATO Noble is an ultrasonic metal powder atomizer with the same basic features as ATO Lab Plus, but modified to work with precious metals and produce high quality precious metal powders. It responds to customer needs for economical atomization of expensive and rare metal alloys. Since there are no limitations on the minimum load and the system is easy to change to another material, the cost effectiveness and freedom of the atomization process are assured.
The ATO Noble is specifically designed to produce precious metals such as
gold, silver, platinum, etc. with high productivity and efficiency. ATO Noble uses Zero Loss Technology which reduces material waste to an absolute minimum. We have achieved this by creating a specially adapted filtration system and a closed loop of gas circulation. Innovative system allows recovery of valuable materials for reuse with a single click of a button.

INSIDE

process chamber stainless steel process chamber cooled with water-jacket material feeder select feedstock form with ATO feeders sonotrode the very heart of the machine, build with patented technology and state-of-the-art nanoalloys, it provides unique process flexibility filters designed to remove small powder particles and excessive fumes ATO powder container compatible with ATO accessories, keeps argon shield recirculation pump maintains the circulation of the argon atmosphere front cover ensures view and protect eyes tig torch welding arc is formed by a electrode and is maintained in a shielding gas covering ultrasonic transducer the “vibration engine” brings energy necessary for eject the particles from melted metal control panel user-friendly software, touchscreen, precise knobs TIG welding source robust power supply guarantees stable process while efficient inverter minimize energy loss

patents

Our ATO ultrasonic metal atomizers are powered by patented by us technology, pivotal for advanced metal powder production.

CN111315513 Device For The Manufacturing Of Spherical Metal Powders By An Ultrasonic Atomization Method

PATENT REQUEST SUBMITTED

EP3638442 A1 Device For The Manufacturing Of Spherical Metal Powders By An Ultrasonic Atomization Method

PATENT REQUEST SUBMITTED

JP2021503044 T2 Ultrasonic spray spherical by way a device for producing metal powder

patent granted

JP7228274 B2 A device for producing a spherical metal powder by an ultrasonic spray method

patent granted

KR102539861 B1 An apparatus for the production of spherical metal powders by ultrasonic atomization method

patent granted

KR20200081444 A By ultrasonic atomization method, apparatus for the manufacture of spherical metal powder

patent granted

PL423410 A1 Device For Producing Spherical Metal Powders By Ultrasonic Atomisation Method

PATENT REQUEST SUBMITTED

PL424869 A1 Device For Ultrasonic Atomisation Of Metallic Materials And Method For Cleaning It

PATENT REQUEST SUBMITTED

PL425803 A1 Ultrasonic Atomiser

PATENT REQUEST SUBMITTED

RU2020118274 A The apparatus for producing spherical powders of metals by ultrasonic spraying

PATENT REQUEST SUBMITTED

RU2020118274 A3 RU2020118274 A3

PATENT REQUEST SUBMITTED

WO19092641 A1 Device For The Manufacturing Of Spherical Metal Powders By An Ultrasonic Atomization Method

PATENT REQUEST SUBMITTED

PL424870 A1 Sonotrode With Internal Cooling System

PATENT REQUEST SUBMITTED

PL425804 A1 Method For Conducting Ultrasonic Atomisation

PATENT REQUEST SUBMITTED

EP3766610 A1 Sonotrode For Ultrasonic Atomization Of Metals And Their Alloys

PATENT REQUEST SUBMITTED

PL430595 A1 Sonotrode For A Device For Ultrasonic Atomization Of Metals And Their Alloys

PATENT REQUEST SUBMITTED

CN113993642 A A Method For Evacuation Of Powder Produced By Ultrasonic Atomization And A Device For Implementing This Method

PATENT REQUEST SUBMITTED

EP3766611 A2 Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

EP3766611 A3 Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

EP3999267 A1 A Method For Evacuation Of Powder Produced By Ultrasonic Atomization And A Device For Implementing This Method

PATENT REQUEST SUBMITTED

IN202127056184 A Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

PL430614 A1 Method For Removing Powder Produced By Ultrasonic Atomization Process And A Device For Implementing This Method

PATENT REQUEST SUBMITTED

US2022305554 AA Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

WO21009683 A1 Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

WO21009683 A4 Method And Device For Producing Heavy Metal Powders By Ultrasonic Atomization

PATENT REQUEST SUBMITTED

WO21009708 A1 A Method For Evacuation Of Powder Produced By Ultrasonic Atomization And A Device For Implementing This Method

PATENT REQUEST SUBMITTED

Learn more about
Technology

Step into the realm of scientific exploration as we delve into the intricacies of metal powder production and Additive Manufacturing.

Fzu Shaping The Future Of Materials Science Cover
Case study microscope Education and Research
FZU - Shaping the Future of Materials Science

FZU has integrated a ATO lab-scale metal atomizer to advance its research capabilities in materials development, focusing on the production and testing of alloys such as titanium, zinc, aluminum, and high entropy alloys. This integration has improved the quality of 3D metal printing parts and enhanced FZU's participation in collaborative industrial projects and innovative materials research.

Cover
Case study Metallurgy
AZTERLAN - Inventing surface conditioning and optimization technology

AZTERLAN has developed and patented a method to improve the surface of iron components. This innovative approach, targeted at improving their resistance to wear and corrosion, is named to revolutionize castings production by applying metal powders on their surface. This innovation expands the possibilities for developing high performance components manufactured using common materials. Technology is based on preparing the surface of the component (substrate) to facilitate the subsequent application of surface coatings by means of laser technologies.

Comparison Of Ultrasonic And Other
Publication DOWNLOAD PDF
Comparison of ultrasonic and other atomization methods in metal powder production

Explore technology of ultrasonic atomization in this insightful research paper. Learn how ultrasonic atomization outperforms traditional gas atomization in producing high-quality metal powders. With detailed analysis on particle size, density, flowability, and microstructure, this paper is a must-read for anyone interested in the future of additive manufacturing.

A Comparative Study On Laser Powder Bed Fusion Wat 1
Publication DOWNLOAD PDF
A Comparative Study on Laser Powder Bed Fusion of Differently Atomized 316L Stainless Steel

The paper focuses on the advancements in Additive Manufacturing (AM) and the growing demand for small gradation metallic powders. It presents a comparative study between two methods of producing 316L stainless steel powders: Ultrasonic Atomization (UA) and Plasma Arc Gas Atomization (PAGA). The study begins by analyzing the powder particle statistical distribution, chemical composition, density, and flowability of the powders produced by both methods. Subsequently, test samples are produced using AM to observe differences in microstructure, porosity, and hardness. The study concludes with an analysis of mechanical properties, including tensile testing with Digital Image Correlation (DIC) and Charpy’s impact tests. The research finds that both ultrasonic and gas atomization methods can produce materials with similar properties, which is significant for the AM industry.

Eth A New Al Cu Alloy For Lpbf Developed Via Ultrasonic Atomization 1
Publication DOWNLOAD PDF
A new Al-Cu alloy for LPBF developed via ultrasonic atomization

Discover the innovative Al-Cu alloy developed for Laser Powder Bed Fusion (LPBF) through ultrasonic atomization. This article delves into the creation of an Al-Cu alloy with additions of Ti, Cr, and Fe, designed to overcome the hot cracking susceptibility of traditional 2xxx aluminum alloys in LPBF. Learn how the addition of Ti and Cr leads to grain refinement and how near-eutectic Fe addition reduces the solidification temperature range, inhibiting hot cracking. With high nanohardness values, this novel alloy holds promise for advanced manufacturing applications.

Kit Metals 11 01723pdf Pdf 1
Publication DOWNLOAD PDF
Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

Discover the intricacies of metal powder production for additive manufacturing with our in-depth article. Dive into the innovative ultrasonic atomization (UA) process that offers flexibility in alloy composition and is ideal for producing refractory metal-based alloys. Compare it with the industrial electrode induction gas atomization (EIGA) process, and explore how these methods affect the size distribution, sphericity, microstructure, and chemical composition of the powders. This article is a treasure trove for those keen on understanding the cutting-edge technologies in powder production for additive manufacturing.

Join us on this exciting journey of research and innovation as we push the boundaries of what's possible with ATO Technology.

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