双耀
Water atomization powder production of powder metallurgy
I. Core Function and Technical Principles
Core Energy Conversion
A high-pressure plunger pump pressurizes water, which is then formed into a high-speed jet through a nozzle, breaking the molten metal stream (such as steel liquid, alloy) into micron-level droplets. Its energy utilization efficiency directly determines the powder fineness and yield:
High-pressure impact fragmentation Higher water pressure leads to a higher proportion of fine particles in the powder.
Two-step atomization mechanism ：
Primary atomization High-pressure water flow impacts a "V-shaped plate jet" Strip-shaped metal stream (not the traditional columnar liquid stream), increasing the contact area and improving the fragmentation efficiency;
Secondary atomization Annular nozzles spray cooling water, causing the particle temperature to drop rapidly to below 60℃, preventing oxidation and particle agglomeration.
Nozzle Collaborative Design
Annular/V-shaped nozzle Optimizes the jet angle to create maximum turbulence and improve metal liquid fragmentation efficiency;
Wear-resistant materials The nozzle insert uses cemented carbide (such as tungsten carbide) to withstand high-pressure wear.
?
II Process Parameter Optimization and Powder Quality Control
Key Process Variables
Metal stream morphology Flat nozzle design forms a strip-shaped liquid stream, increasing metal flow rate compared to columnar liquid streams and shortening atomization time;
Temperature control Atomization termination temperature <60℃ to avoid powder oxidation.
Powder Performance Improvement
Morphology control High-pressure impact forms Irregular angular particles , improving press formability;
Low oxygen technology Closed-loop water + inert gas protection, oxygen content reduced by 40% compared to traditional processes.
?
? ? III. Technological Evolution and Innovation Directions
High-pressure, high-flow rate trend
Intelligent control Variable frequency speed regulation + pressure sensor dynamic pressure stabilization (fluctuation <±5%), adapting to smelting fluctuations.
Energy saving and reliability breakthrough
Permanent magnet motor drive Energy consumption reduced by 30%, temperature rise ≤55℃ (guaranteed by forced lubrication system);
Wear resistance upgrade Plunger cemented carbide, lifespan extended by 3 times.
System integration innovation
Two-step atomization device Decomposes energy exchange (primary fragmentation) and heat exchange (secondary cooling) to improve fine powder rate;
?
?
? ? IV. Application Cases and Technical Economics
Industrialization achievements
Cost comparison Water atomization method shortens the process by 30% and reduces raw material costs compared to the reduction method.
Typical troubleshooting
| Problem | Cause | Solution |
|---|---|---|
| Nozzle blockage | Water impurities/metal slag | Install a 5 μm precision filter |
| Seal leakage | High-pressure wear/thermal deformation | Ceramic plunger + nano-coating seal |
| Pressure fluctuation | Insufficient liquid inflow/cavitation | Variable frequency steady flow + accumulator buffer |
?
? ? V. Challenges and Future Directions
Intelligent upgrade Digital twin system predicts pump and valve failure (such as pressure harmonic analysis);
Green manufacturing Wastewater recycling (closed-loop water system) + waste heat recovery technology.
?
? ? Summary
High-pressure plunger pumps in water atomization powder production have been upgraded from "power sources" to Core of precision atomization control system Its high-pressure, intelligent (variable frequency + Internet of Things) and long-life (wear-resistant coating) evolution has driven powder metallurgy towards fine-grained, low-oxidation high-end applications. Future breakthroughs are needed in ultra-high-pressure sealing, digital maintenance, and low-carbon design to meet the stringent demands of emerging fields such as MIM and 3D printing for ultrafine powders.
The 17th China International Powder Metallurgy and Hard Alloy Exhibition
The 2025 17th China International Powder Metallurgy and Hard Alloy Exhibition from March 10-12, 2025, at the Shanghai World Expo Exhibition and Convention Center, Hall H1, B425. We welcome guests to visit.
"Private custom" product design, reliable and durable finished products
"Private custom" like product design, reliable and durable finished products, professional and timely after-sales service. It is the "three basic concepts" that the company adheres to from the beginning until today ".
Experienced market research team, independent product development concept
We have experienced mature market research team, independent product research and development concept, professional design and manufacturing technology so that the company's products can be adjusted according to the specific requirements of customers timely design
Contact CONTACT
Address： No.2 Road, Xiaodian Town Industrial Zone, Beichen District, Tianjin
