Continuous and Cost-efficient Production of Metal Powders for the Next Breakthrough in Metal Additive Manufacturing

Abstract

This study explores a novel approach of metal powder production, aiming to drive the cost-effectiveness and quality of powders for sustainable advancement in metal additive manufacturing (AM). The SMS group has refined conventional powder production for AM requirements. Additionally, in collaboration with a partner, an innovative continuous powder production process has been developed, allowing for cost-effective, large-scale production of up to 4,000 tons annually. This continuous process significantly enhances capacity, reduces production costs, and offers economies of scale. The process involves two vacuum induction melting (VIM) furnaces continuously maintaining liquid melt, atomized successively through an exchangeable nozzle under vacuum conditions, ensuring high-quality metal powders comparable to traditional methods.