Producing spherical Niobium metal powder and High-Entropy Alloys with Ultrasonic Atomization

In this production cycle, niobium rods in diameters of 2.4 mm, 4 mm, and 6 mm were atomized using standard frequency configuration under inert gas shielding. The 2.4 mm and 4 mm rods were processed in fully automated mode, with continuous feeding and automatic torch movement. For the 6 mm rod, semi-automatic operation was applied, where the operator occasionally rotated the rod using a manual control knob.

Despite the variation in input geometry, the process remained stable and efficient across all cases, demonstrating ATO Lab Plus’s flexibility in metal powder production for reactive and high-melting-point metals.

As a refractory metal, niobium plays a crucial role in high-entropy alloy development, where it contributes to mechanical strength, creep resistance, and phase stability at elevated temperatures. These alloys are central to cutting-edge applications in:

• Hypersonic flight systems
  
• Turbine and propulsion components
  
• Biomedical implants
  
• Next-gen electronics and superconductors

In the context of Additive Manufacturing, having access to custom-tailored niobium powder opens the door to new geometries, gradients, and hybrid materials that were previously difficult or impossible to achieve.

This demonstration reinforces the ability of ATO Lab Plus to atomize high-melting-point metals with precision and purity. Its modular design, inert gas operation, and compatibility with reactive metals make it a valuable tool for any lab or facility focused on AM powder development, HEA exploration, or functional material innovation.

The system provides:

• Consistent powder quality across feedstock diameters
• Automation for hands-free processing
• High repeatability for R&D or low-volume production
• Compact, plug-and-play usability in lab environments

By producing niobium powder directly from rods using ATO Lab Plus, users gain full control over their metal powder production, enabling faster experimentation and development of next-generation materials, including complex high-entropy alloy systems.