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From Concept to Creation, Taking AM to Full-Scale Production

With industry-leading AM expertise, Carpenter Additive identifies the right applications for AM technologies, working with customers to create a roadmap that enables them to reach full-scale production.

Unlock Your AM Potential

Today, from concept to creation, Carpenter Additive enables you to unlock the potential of Additive Manufacturing to take your designs into full‑scale AM production.

With experts on hand to support the selection and qualification of AM powders, Carpenter Additive has the experience to adapt existing chemistries and to develop new materials that enable customers to achieve their desired mechanical properties.

Carpenter Additive can support customers throughout all stages of the AM lifecycle. From providing guidance on the right material selection for the needs of specific applications to optimizing AM build processes and parameters. Guidance is available to support users on their AM journey, ensuring the reliability of final builds.

With AS9120, AS9100, ISO9001 and ISO13485 certifications, Carpenter Additive has a proven track record of defining and qualifying AM processes across applications and safety-critical industries.

With full machining, heat-treatment, HIP, post-build clean-up and inspection capabilities, totally mechanical, physical characterization and complete qualification data packages are available.

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Methods of AM Metal Powder Production

Gas Atomization

The most common method of metal powder production, producing mostly spherical powder...

The elemental feedstock is melted under an air or inert gas blanket, or under vacuum. The chamber is then backfilled with gas to force molten alloy through a nozzle where high-velocity air, N, He or Ar gas impinges onto the flowing melt and breaks it up. The powder is mostly spherical, with some asymmetric particles and satellites present. A satellite is when a smaller particle sticks to a larger one during solidification. Heat sizes range from 5kg to 3000kg. Size ranges from 0 to 500 micron. Yield within 20-150 micron range varies from 10 to 50% of the total. Mostly used for Ni, Co and Fe alloys, also available for Ti and Al alloys.

Water Atomization

Similar to gas atomization but using water as the medium, producing irregular shaped powder particles mostly for unreactive materials...

Used mostly for unreactive materials such as steels, it produces irregular shaped powder particles.

Plasma Atomization

A relatively new technique producing high quality and extremely spherical metal powder...

Wire feedstock is fed into a plasma torch that, with the aid of gases, atomizes the powder. Size ranges from 0 – 200 micron. Limited to alloys that can be formed into a wire feedstock.

EIGA (Electrode Induction melting Gas Atomization)

A cost-effective, clean process for small batches, producing small diameter powder most economic with reactive alloys...

Works with all metal alloys but is most economic with reactive alloys like Ti. Feedstock, in the form of bar, is rotated and melted by an induction coil. A film of molten metal flows downwards into a gas stream for atomization. Therefore, material does not come in contact with either crucible or electrode during process. Powder size is 0 to 500 micron and morphology is similar to gas atomized. Process is cost-effective, clean, good for small batches and produces small diameter powder.

PREP (Plasma Rotating Electrode Process)

Similar to EIGA process, producing extremely spherical metal powders with yields below 100 microns...

Similar to EIGA process but the rotating feedstock bar is melted when it comes into contact with a plasma. Metal powders are extremely spherical but yields are limited below 100 micron, so price can be very high.

Centrifugal Atomization

A smart compromise between Gas Atomized and Plasma Atomization, generating more spherical powder with lower entrapped gas porosity...

A simple process that is not in wide-spread use. A good compromise between Gas Atomized and Plasma Atomization. Generates powder that is more spherical and has lower entrapped gas porosity than Gas Atomization but not to the quality of Plasma Atomization or PREP. However, is cheaper than both PREP and Plasma Atomization. Best suited to larger batch sizes of less reactive low melting temperature alloys, but can also make Nickel superalloys.

Plasma Spheroidization

High energy plasma produces highly spherical, fully dense AM metal powders...

Carpenter Additive uses high energy plasma to produce highly spherical and dense AM metal powders. Carpenter Additive’s system uses plasma to transform agglomerated powders produced by spray drying or sintering techniques, or angular powders produced by conventional crushing methods, into spherical powder. Powder is gravity fed from the top and it is sprayed through the plasma by using various nozzle types depending on specific powder characteristics. Individual powder particles are completely melted and solidify in a spherical shape. Plasma treated powder is fully dense and highly spherical. Surface contamination is also significantly reduced through the vaporization of impurities. At Carpenter Additive we have a high level of expertise in AM and a long experience of working with leading companies within the aerospace, biomedical, and automotive industries. We utilise this knowledge and the capabilities of plasma technology to produce highly spherical and low contamination metal AM powders: High melting temperature refractory metals such as Ta, W, Nb, and Mo Customer specific metallic and ceramic compositions improve flowability and reduce contamination levels of standard products produced by gas or water atomization, reconditioning metal powders that have been used several times within an AM machine. Powder purity, morphology, and surface contamination change during use, especially Oxygen, Nitrogen, and Hydrogen.

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Latest News and Thought Leadership

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