ATO Lab Plus Atomizer
Quick production of high quality metal powders.
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Technology:
Ultrasonic atomization
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Description
ATO LAB Plus is a unique compact machine for metal powders production using the latest ultrasonic atomization technology. This revolutionary solution enables the rapid production of metal powders with a narrow particle size distribution. ATO LAB Plus can produce several hundred grams of metal powder per hour with particle sizes ranging from 20 to 120 microns. The hermetically sealed process chamber allows the production of powders of reactive metals and their alloys such as titanium or aluminum. The production is based on ultrasonic atomization technology. In this way powders can be produced with almost any particle size limitation. The ATO LAB Plus has compact dimensions, which allow it to be used efficiently even in small research laboratories. The ATO LAB Plus is no larger than an ordinary office cupboard. ATO LAB Plus is equipped with specialized, versatile and user-friendly software, and the operator can control the process from the touch screen display. The main objective was to create a system that can be used even by a novice. The new MBRFS module provides greater efficiency with a multiple bar feed mechanism, an automatic magazine feeder for the use of multiple bars n a single atomization process.
ATO INSIDE
REACTIVE AND NON-REACTIVE METALS
ATO LAB Plus can produce several hundred grams of metal powder per hour with particle sizes from 20 to 120 microns. The hermetically sealed process chamber allows the production of powders of reactive metals and their alloys such as: titanium or aluminum.
LOW WASTE
ATO LAB atomizer is a new way of creating high quality metal powders. This method is based on a special technology that was developed for universities, research departments and service bureaus. However, due to their reliability and efficiency, these atomizers have also found applications in industry.
OPEN ATOMIZATION PARAMETERS
ATO Lab Plus is specifically designed to eliminate the limitations of automation. The device has a compact size, so it can be used even in confined spaces. It is equipped with innovative technology and does not require complex infrastructure, thus reducing operating costs and providing a quick return on investment.
ULTRASONIC POWDER ATOMIZATION TECHNOLOGY
Ultrasonic vibration technology is used to break molten metal into small droplets, which rapidly solidify into metal powder in an inert gas atmosphere. The metal powder size produced depends on the frequency of the ultrasonic waves, with higher frequencies producing smaller particles and lower frequencies producing larger particles. Factors affecting particle size and distribution are viscosity, density, ultrasonic amplitude and atomizer design. Ultrasonic atomization of metal powder using ATO technology is a process in which metal powder is melted using an electric arc. Ultrasonic vibrations are then transmitted into the molten metal, creating capillary waves. These waves eject metal droplets, which are rounded and cooled before being collected and sorted. The result is almost perfectly spherical metal droplets.
METAL POWDER MAIN APPLICATIONS
The resulting metal powders are used for 3D printers using Laser Powder Bed Fusion (LPBF) technology, also known as Selective Laser Melting (SLM). This is a metal 3D printing technology that uses a high-powered laser to selectively melt and sinter metal powder particles together to create a solid part. In this technology, a layer of metal powder with a standard particle distribution of 10-60 microns is applied to the working platform. A powerful laser is then used to selectively melt and sinter the powder particles together, layer by layer, until the part is complete. The process is performed in a controlled atmosphere to prevent oxidation and ensure high quality parts are produced. LPBF/SLM is used in a variety of industries including aviation, automotive, medical and industrial manufacturing. It is especially useful in applications that require high strength and high temperature resistant parts with complex geometries.
Another area of application is Direct Energy Deposition technology. DED is a 3D printing technology that uses a high-energy source such as a laser or electron beam to melt and deposit metal powders or wires onto a substrate. This technology is capable of producing metal parts with high strength, high density and complex geometries. DED is used in various industries such as repair and maintenance to refurbish damaged turbine blades or engine parts.
ATO LAB PLUS ADVANTAGES
Compact size, suitable for use in small spaces
With its dimensions of 78×42×60in / 200x107x154cm, weight of 1543lbs / 700kg and equipped with roller wheels it is quite mobile and easy to transport.
Innovative technology to ensure efficient operation
ATO Lab Plus is a new device that creates high-quality metal powders for use in 3D printing. It can produce various types of metal powders, including aluminum, copper, stainless steel, titanium, and other alloys.
Low operating costs and quick investment return
ATO Lab Plus is specifically designed with innovative technology and does not require complex infrastructure, thus reducing operating costs and providing a quick return on investment.
ATO Lab Plus is a device that can help you increase your efficiency and save money. In terms of usability, the ATO Lab Plus has an intuitive control system with a clear interface and precise parameter control. Operators can easily adjust parameters to achieve optimal powder properties for their specific needs. This ease of use makes the ATO Lab Plus ideal for research and development as well as industrial production on a large scale. 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.
list of successfully atomized ALLOYS
Steel is the most widely used material in almost all industries due to its low price, high mechanical properties and a wide range of heat treatments that can help tailor the material for individual purposes. The atomization process of steel is one of the simplest and most balanced in terms of quality, yield and process stability. Its characteristics allow it to be used as a primary benchmark material for the ultrasonic atomization process. The distribution of the powder is very homogeneous with a narrow range of metal powder, which is very desirable for some manufacturing methods.
ATOMIZED ALLOYS ON ATO
- 42CrMo4
- AMS5832
- Fe 99,5%
- FeMn
- PH177 Garba
- SS304
- SS316L
Titanium is one of the most promising materials of the 21st century, having one of the highest values of strength to density and corrosion resistance. Similar to steel, it can be easily atomized using ultrasonic atomization. The process can be very stable which has immense potential for automation. Considering the high prices of titanium alloys and its powders, ultrasonic atomization has one of the best commercial perspectives. Nevertheless, one of the main challenges is the rate of absorption of oxygen and nitrogen, which places additional requirements for the atomization process conditions.
ATOMIZED ALLOYS ON ATO
- Ti OCT 1-90013-81
- Ti5Al2.5Sn
- TiAl
- TiMoSi
- Titanium Gr.1
- Titanium Gr.2
- Titanium Gr.5 (Ti6Al4V)
Nickel-based alloys are mainly used in the aerospace industry due to their high temperature and corrosion resistance combined with good ductility and strength. The atomization of the material is very stable, similar to steel and titanium. Oxygen pick-up is exceptionally low, and the material is homogeneous. Due to these advantages, ultrasonic atomization seems to be a good and efficient method for scrap recycling. Some international companies may be interested in implementing ultrasonic atomization to reduce their carbon footprint and increase the ESG rating.
ATOMIZED ALLOYS ON ATO
- Inconel 625
- Inconel 718
- Ni 99%
- NiTi
- NiTiHf
Aluminum is one of the most commonly used non-ferrous alloys due to its low density, relatively high strength and good corrosion resistance. Atomization of the metal and its alloy is quite challenging due to several issues. However, the powder meets the requirements for most 3D printers with a sphericity of 0.93 and an eq. grain diameter of approximately 50 µm. One of the main challenges with aluminum and its alloys is their affinity for oxygen, which creates a large surface tension between the molten metal and the sonotrode tip which decreases the contact zone. Furthermore, a thin layer may still be present on the surface of the powder. Based on the research conducted, higher frequency allows for a more stable atomization process that can be performed with minimal operator interference.
ATOMIZED ALLOYS ON ATO
- Al 99,99%
- Al4047
- Al5183
- Al7075
- AlCoCrFeNi
- AlMg
- AlMgCu
- AlMgSc
- AlSi10Mg
The lightest construction material which has decent strength and the highest specific strength for metal alloys. Magnesium alloys can be used where weight reduction is a key feature. The atomization of magnesium tends to be challenging, but by optimizing the process it is possible to obtain powder with high sphericity. Higher frequency piezoelectric generators can further stabilize the process. It is also worth noting that the problem with most magnesium alloys is very rapid oxidation, which also applies to atomized powder. Magnesium powder is highly reactive and the ATO Lab Plus system has one of the best coating systems which increases the safety of the process.
ATOMIZED ALLOYS ON ATO
- MgAl9Zn1
- AZ31
- WE54
This group includes the most resilient materials that are hard to manufacture and form using conventional technologies. The most common materials in this group are tungsten, molybdenum and tantalum. Ultrasonic atomization enables to produce a fine powder suitable for most applications. It is worth mentioning that 3D Lab has dedicated features that reduce the wear of the working chamber, which is an issue for all refractory materials. The atomization process is stable and can be partially automated.
ATOMIZED ALLOYS ON ATO
- Nb 99%
- Ta 99%
- W90Ni7Fe3
- MoSi2
Gold, platinum and silver can be successfully atomized to produce fine metal powders. This opens new shaping possibilities where the only limit is the designer’s imagination. Furthermore, by using ATO Noble it is possible to achieve zero waste production, which is the most important feature in the jewelry industry. It is also worth mentioning that the chemical composition remains the same after atomization, which helps to maintain the right precious metal standard.
ATOMIZED ALLOYS ON ATO
- Ag 99%
- Au 9ct
- Au 18ct
- Au 99,99%
- Au 99,99%
- Ir 99%
- Pt alloys
Copper and its alloys are best known for their electrical and thermal conductivity. The material has high resistance to corrosion and is a semi-precious material. The material enforces the use of higher currents despite relatively low melting temperature. Nevertheless, metal powder has remarkably high sphericity and homogeneity. Atomization of zinc-containing brass can be challenging due to fuming at high temperatures. Careful parameter optimization is required.
ATOMIZED ALLOYS ON ATO
- CuAlNiFe
- CuCrZr
- CuM1E
- CuMnAl
- CuNi3Si
- CuSn
High entropy alloys are being developed at many research institutions. The results indicate that some HEAs have significantly better strength-to-weight ratios, with higher levels of fracture resistance, tensile strength, and corrosion and oxidation resistance than conventional alloys. The atomization of HEA is highly dependent on the chemical composition of the material. It is easier to atomize materials that are easy to melt and have relatively low surface tension. Depending on the chemical composition of the alloy, the melting tip material core must be selected individually.
ATOMIZED ALLOYS ON ATO
- CoCrFeMo
- NiCrFe
- FeNiCrMo
- CoCrFe
- FeNiAlCr
In addition to the common metals, we have successfully atomized metals for the semiconductor industry, such as MoS2 and others. Spherical metal powders were obtained in laboratory quantities, which can be further processed by special AM processes. We have also had success with some zirconium bulk metallic glasses, although in small quantities. Other meltable and weldable materials can be atomized with appropriate process parameter selection. Based on melting temperature, affinity to oxygen, chemical composition requirements, it is possible to obtain the appropriate atomization parameters.
ATOMIZED ALLOYS ON ATO
- MoS2
- B4C
ato patents
ATO PERIPHERALS
The ATO atomizers configuration is flexible and based on a patented ultrasonic atomization technology. The system can be easily customized to meet the individual needs of the customer. ATO is a modular system with the future potential to operate with sets of many units in an interconnected network.
- Brand 3D Lab
- Country of origin Poland
- Process Metal powders production
- Technology Ultrasonic atomization
- Meltimg method TIG
- Sonotrode type Half-wave nanoalloy sonotrode - patent pending
- Inert gas flushing method Vacuum pump
- Cooling method Liquid
- Processable materials Non-reactive & reactive alloys (e.g. Ti, Al., Zr alloys, intermetallics e.g. Zr-based bulk metalic glass TiAl, NiAl, NiTi) and other refractory metals
- Powder quality Low oxygen content, Narrow PSD, High flowability, Spherical particle shape
- PSD (particle size distribution) 20-120um
- Powder collecting system Cyclone
- Protective atmosphere preparation time <5 min.
- Input material Wire / rod (upgrade: SingleBoltFS)*
- Certification CE
- Ultrasonic frequency 35 kHz (+ upgrade to higher frequency)
- O2 level < 150 ppm
- System throughput up to 0,3l/h
- Weight 600 kg.
- Dimensions 1994x813x1138 mm
- Air supply Compress air station
- Inert gas Argon
- Power supply 400V, 20KVA / 3 phase
- Cleaning unit Ultrasonic cleaner
- Powder recycling system Sieving unit
- Water cooling External chiller
- Warranty 12 months
- Material reactive
Materials
- reactive
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