Inert Gas Atomization Process Variables for Tool Steel Powder Production
Melt superheat, gas-to-metal ratio, and aspiration pressure dictate particle size distribution, cooling rate, and oxide pickup in tool steel powder production.
EIGA Process
Meaning
Powder metallurgy manufacturing systems convert solid metal feedstocks into fine spherical alloy powders using contactless induction melting and gas atomization. The EIGA process melts a rotating prealloyed bar using an induction coil without ceramic crucible contact before atomizing the molten stream with high-pressure inert gas. This method produces pure spherical powders free of refractory oxide inclusions for additive manufacturing and specialized electrode production.
The technology applies to reactive or refractory metal alloys and excludes continuous liquid metal casting systems.
Melting Mechanism
High frequency electromagnetic fields heat the rotating metal rod until a continuous liquid stream drops from the tip. Eliminating crucible contact in the EIGA process prevents ceramic contamination in titanium and zirconium alloy powders. Inert argon gas jets disintegrate the falling molten stream into fine liquid droplets that solidify rapidly in flight.
Atomization parameters govern particle size distribution and powder sphericity.
Powder Quality
Spherical particle geometry improves powder flowability and packing density during additive manufacturing layer deposition. Oxygen contamination remains extremely low throughout the EIGA process due to sealed argon gas recirculation.
Sourcing Standard
Medical and aerospace material buyers mandate melt cleanliness standards to avoid fatigue failure initiation sites. Powder yield within target particle size distributions dictates unit production economics for specialty alloy producers. Inspection certificates verify particle shape factors and chemical purity before shipment acceptance.