Revolutionizing magnesium metal powder production with Ultrasonic Metal Atomization

High-quality magnesium metal powders are critical for producing components that meet stringent performance and safety standards. The uniformity in particle size distribution and the purity of the powder directly impact the mechanical properties and reliability of the final product. Ensuring superior powder quality is paramount for industries aiming to reduce weight without compromising strength or integrity of final product.

The ATO Induction Melting System (IMS) integrates Ultrasonic Metal Atomization technology to produce high-quality magnesium powders. In this system, the IMS efficiently melts magnesium with precise temperature control, ensuring minimal contamination and maintaining the integrity of the metal. Once molten, the magnesium is subjected to ultrasonic vibrations, which atomize the molten metal into fine droplets. This ultrasonic process results in powders with uniform particle size, high purity, and consistent spherical shapes. By combining induction melting and ultrasonic atomization within the IMS, this method delivers superior magnesium powders that meet the rigorous standards required for advanced applications

We prepared material report from ultrasonic atomization of ZX00 magnesium alloy in the form of rods with Single Rod Feeding System on the IMS module. We achieved good particle size distribution based on the conducted tests and atomization was quite easy. The properties of this alloy increase its potential for use in orthopedic and other medical applications, particularly in the development of lightweight and biocompatible components. We have also succesfully manufactured metal powder from other magnesium alloys, including WE43, about which we have published an research raport.

An insightful review published in the International Journal of Lightweight Materials and Manufacture (Volume 7, Issue 1, January 2024, Pages 184-213), titled Additive Manufacturing of Magnesium Alloys: Characterization and Post-Processing by Shambhu Kumar Manjhi et al., discusses the challenges of using magnesium in additive manufacturing. The article highlights the high requirements for powder quality, safety, and performance in advanced technologies.

Ultrasonic atomization technology addresses these challenges by producing magnesium metal powders with superior particle distribution and purity. This advancement is key to overcoming hurdles in producing lightweight, high-performance components for automotive and aerospace applications, driving innovations in fuel efficiency and structural integrity.

We support researchers in the research and development of new magnesium alloys with equipment capable of producing high-quality powders in both laboratory and small-scale production environments. The latest developments in producing magnesium metal powders are pushing the boundaries of what's possible in advanced manufacturing. By producing premium-quality magnesium powders, manufacturers can create components that require precise specifications and exceptional performance. As mentioned earlier, ultrasonic atomization technology has revolutionized the production of these powders, ensuring uniform particle size and superior purity by contactless induction melting of magnesium rods with SRFS.

As industries continue to seek materials that offer both lightweight properties and high strength, the importance of superior magnesium metal powders will become increasingly significant. By embracing these advanced materials, manufacturers can achieve unprecedented levels of efficiency and performance. This not only enhances product quality but also solidifies the future of magnesium metal powders in advanced manufacturing sectors like automotive, medical, aerospace and beyond.