Powder spheroidizing via fluidized bed

Patent metadata

Field	Value
Publication number	US-2016221084-A1
Application number	US-201415021575-A
Country	US
Kind code	A1
Filing date	Jul 30, 2014
Priority date	Aug 12, 2013
Publication date	Aug 4, 2016
Grant date	—

Abstract

One embodiment includes a powder spheroidizing method. The method includes loading a powder into a fluidized bed assembly, fluidizing at least some of the powder in the fluidized bed assembly using an inert gas, and heating the powder while fluidized in the fluidized bed assembly.

First claim

1 . A powder spheroidizing method comprising:
loading a powder into a fluidized bed assembly; fluidizing at least some of the powder in the fluidized bed assembly using an inert gas; and heating the powder while fluidized in the fluidized bed assembly.

2 . The method of claim 1 , wherein the powder is heated by a furnace within which the fluidized bed assembly is positioned.

3 . The method of claim 1 , wherein the powder is heated by the inert gas which is heated by a gas heater.

4 . The method of claim 1 , wherein the powder is heated to a temperature below a melting point of the powder.

5 . The method of claim 4 , wherein the powder is heated to a temperature at or above a temperature at which the powder softens.

6 . The method of claim 1 , wherein the powder is heated until substantially all particles of the powder are spheroidized.

7 . The method of claim 1 , further comprising removing the powder from the fluidized bed assembly.

8 . The method of claim 7 , further comprising additively manufacturing an article using the powder removed from the fluidized bed assembly.

9 . The method of claim 1 , wherein the inert gas is introduced into an outer chamber of the fluidized bed assembly and enters an inner chamber of the fluidized bed assembly where the inert gas fluidizes at least some of the powder.

10 . A powder spheroidizing apparatus for spheroidizing a powder, the apparatus comprising:
a fluidized bed assembly; a heat source for introducing heat into the fluidized bed assembly; a powder within the fluidized bed assembly; and a plate disposed within the fluidized bed assembly.

11 . The apparatus of claim 10 , wherein the powder is selected from a group consisting essentially of: metal, ceramic, glass, and polymer powder.

12 . The apparatus of claim 10 , wherein the plate is disposed within an inner chamber of the fluidized bed assembly.

13 . The apparatus of claim 12 , wherein the fluidized bed assembly further comprises:
an outer chamber with an inlet; and the inner chamber positioned inside of the outer chamber, wherein the inner chamber is in fluid communication with the outer chamber, wherein a fluidizing gas is introduced through the inlet of the outer chamber.

14 . The apparatus of claim 13 , wherein the heat source is a gas heater through which the fluidized gas is passed before entering the inlet of the outer chamber.

15 . The apparatus of claim 13 , wherein the fluidizing gas is an inert gas.

16 . The apparatus of claim 15 , wherein the inert gas is selected from the group consisting of nitrogen and argon.

17 . The apparatus of claim 13 , wherein the heat source is a furnace within which at least a portion of the fluidized bed assembly is positioned.

18 . A method for spheroidizing powder, the method comprising:
loading a powder into a fluidized bed assembly; fluidizing at least some of the powder in the fluidized bed assembly using an inert gas; heating the powder while fluidized in the fluidized bed assembly to a temperature ranging between a temperature at or above which the powder softens and below a melting point of the powder, wherein the powder is heated until substantially all particles of the powder are spheroidized; removing the powder from the fluidized bed assembly; and additively manufacturing an article using the powder removed from the fluidized bed assembly.

19 . The method of claim 18 , wherein the powder is heated by a furnace within which the fluidized bed assembly is positioned.

20 . The method of claim 18 , wherein the powder is heated by the inert gas which is heated by a gas heater.

Assignees

• United Technologies Corp

Inventors

• Klecka Michael A
• She Ying
• El-Wardany Tahany Ibrahim
• Nardi Aaron T

Classifications

• B22F1/065

  Spherical particles · CPC title

• B22F1/142

  Thermal or thermo-mechanical treatment · CPC title

• B01J2/16 Primary

  by suspending the powder material in a gas, e.g. in fluidised beds or as a falling curtain · CPC title

• B22F1/0085

  Operations & Transport · mapped topic

• B22F2201/11

  Argon · CPC title