A powder production system

Patent metadata

Field	Value
Publication number	US-2024342796-A1
Application number	US-202218701517-A
Country	US
Kind code	A1
Filing date	Oct 11, 2022
Priority date	Oct 19, 2021
Publication date	Oct 17, 2024
Grant date	—

Abstract

This invention relates to more than one powder (T) suitable for use in a powder bed additive manufacturing method in a user-predetermined amount, a primary material (M) suitable to be brought into powder (T) form and having a user-predetermined composition content, a secondary material (N) with a composition content that is almost entirely different from that of the primary material (M), more than one waste gas (G) that is released when the primary material (M) and the secondary material (N) are brought into a powder (T) form and that is a waste product, at least one feeding unit (2) enabling the primary material (M) and the secondary material (N) to be fed, a first transmission line (3) into which the primary material (M) and the secondary material (N) are fed by means of the feeding unit (2), at least one plasma torch (4) enabling a powder (T) to be obtained from the primary material (M) and the secondary material (N) fed therein by means of the first transmission line (3) using a plasma atomization method, at least one powder composition meter (501) acquiring the composition content data of the powder (T).

First claim

1 . A powder production system ( 1 ) for more than one powder (T) suitable for a powder bed additive manufacturing method in a user-predetermined amount, comprising:
a primary material (M) suitable to be brought into powder (T) form and having a user-predetermined composition content, a secondary material (N) having a composition content that is almost entirely different from that of the primary material (M), more than one waste gas (G) that is released when the primary material (M) and the secondary material (N) are brought into a powder (T) form and that is a waste product, at least one feeding unit ( 2 ) enabling the primary material (M) and the secondary material (N) to be fed, a first transmission line ( 3 ) into which the primary material (M) and the secondary material (N) are fed by means of the feeding unit ( 2 ), at least one plasma torch ( 4 ) enabling a powder (T) to be obtained by means of a plasma atomization method from the primary material (M) and the secondary material (N) fed therein through the first transmission line ( 3 ), at least one powder composition meter ( 501 ) acquiring the composition content data of the powder (T), at least one waste gas composition meter ( 502 ) acquiring the composition content data of the waste gas (G), at least one composition meter ( 5 ) acquiring the composition content data of the powder (T) and waste gas (G), and at least one control unit ( 6 ) enabling the feeding rates of the primary material (M) and the secondary material (N) to be changed by means of the feeding unit ( 2 ) to almost completely approximate the composition content data of the powder (T) and waste gas (G) obtained from the composition meter ( 5 ) to the user-determined target composition content data of the powder (T) and waste gas (G).

2 . The powder production system ( 1 ) according to claim 1 , wherein the control unit ( 6 ) compares the amounts converted from the primary material (M) and secondary material (N) into powder (T) and waste gas (G) for each element to the user-determined target composition content of the powder (T) and waste gas (G) based on the principle of mass conservation using the composition content data of the waste gas (G) and powder (T) and changes the feeding rates of the primary material (M) and secondary material (N) and the plasma torch ( 4 ) parameters simultaneously.

3 . The powder production system ( 1 ) according to claim 1 , comprising a second transmission line ( 7 ) enabling the transmission of the powders (T) obtained in the plasma torch ( 4 ), a first powder chamber ( 8 ) located on the second transmission line ( 7 ) enabling the collection of the powders (T) obtained in the plasma torch ( 4 ), at least one pump ( 9 ) located on the second transmission line ( 7 ) and enabling the powders (T) to be transmitted along the second transmission line ( 7 ), and at least one exhaust ( 10 ) enabling the waste gases (G) to be discharged from the second transmission line ( 7 ).

4 . The powder production system ( 1 ) according any to claim 1 , wherein the control unit ( 6 ) enables the primary material (M) and the secondary material (N) to be fed through the first transmission line ( 3 ) to the plasma torch ( 4 ) by means of the feeding unit ( 2 ), the primary material (M) and the secondary material (N) to be converted into the form of powder (T) by a plasma atomization method in the plasma torch ( 4 ), the composition content data of the powder (T) and waste gas (G) to be obtained by means of the powder composition meter ( 501 ) and the waste gas composition meter ( 502 ) and the obtained composition content data to be transmitted to the control unit ( 6 ), the composition content data of the powder (T) and waste gas (G) transferred from the composition meter ( 5 ) to be compared to user-predetermined target composition content data of the powder (T) and waste gas (G) in the control unit ( 6 ), the feeding rates of the primary material (M) and the secondary material (N) to be changed by means of the feeding unit ( 2 ) based on this comparison made, such that the powder (T) is almost exactly equalized to user-determined target composition content data.

5 . The powder production system ( 1 ) according to claim 1 , comprising a first powder chamber ( 8 ) located on the second transmission line ( 7 ) and enabling the powders (T) of a user-determined macro-, micro—or nano-order size to be collected, and a second powder chamber ( 11 ) located on the second transmission line ( 7 ) enabling the powders (T) of almost larger sizes than the powders (T) collected in the first powder chamber ( 8 ) to be collected in itself.

6 . The powder production system ( 1 ) according to claim 1 , wherein the control unit ( 6 ) a enables ny production parameter and outputs generated using a machine learning method with the data previously defined by the user in the control unit ( 6 ) to be evaluated and the feeding rates of the primary material (M) and the secondary material (N) to be changed by means of the feeding unit ( 2 ), enables the powder (T) composition to be almost exactly approximated to the user-predetermined composition content data.

7 . The powder production system ( 1 ) according to claim 1 , wherein the control unit ( 6 ) enables the user to change the feeding rates of the primary material (M) and the secondary material (N) for reducing the cost of the powder (T) produced.

8 . The powder production system ( 1 ) according to claim 1 , wherein the composition meter ( 5 ) measures the inorganic material composition of powders (T) by an X-ray fluorescence (XRF) method and transmits the obtained measurement data to the control unit ( 6 ) for varying the feeding rates of the primary material (M) and the secondary material (N).

9 . The powder production system ( 1 ) according to claim 1 , wherein the composition meter ( 5 ) measures the organic material composition by an inert gas fusion (IGF) based combustion method and transmits the obtained measurement data to the control unit ( 6 ) for varying the feeding rates of the primary material (M) and the secondary material (N).

10 . The powder production system ( 1 ) as claimed in claim 1 , wherein the control unit ( 6 ) changes the parameters of the plasma torch ( 4 ) so that the composition content data of the powder (T) and waste gas (G) are almost entirely approximated to user-determined target composition content data of the powder (T) and waste gas (G).

11 . The powder production system ( 1 ) as claimed in claim 4 , comprising a first valve ( 12 ) located on the second transmission line ( 7 ), the first powder chamber ( 8 ) and/or the second powder chamber ( 11 ) for enabling the desired macro-, micro— or nano-sized powders (T) to be separated and transmitted to the relevant powder chamber by means of its sieve structure, and by being brought to an open or closed position by the control unit ( 6 ), enabling the powders (T) that have not reached the target composition ratio to be transmitted to the relevant powder chamber.

12 . The powder production system ( 1 ) as claimed in claim 1 , comprising at least one third transmission line ( 13 ) on which the composition meter ( 5 ) is located and to which only the amount of powder (T) that is required to take a sample from the powders (T) obtained in the plasma torch ( 4 ) is transferred, at least one plasma torch valve ( 14 ) that enables a user-predetermined amount of powder (T) to be transferred to the third transmission line ( 13 ) to take a sample from the powder (T) obtained in the plasma torch ( 4 ) and is triggered by the control unit ( 6 ).

13 . The powder production system ( 1 ) as claimed in claim 1 , comprising at least on

Assignees

• Tusas Turk Havacilik Ve Uzay Sanayii Anonim Sirketi

Inventors

• Altinok Sertac

Classifications

• B22F2009/0836

  with electric or magnetic field or induction · CPC title

• B22F9/082 Primary

  atomising using a fluid (using centrifugal force B22F9/10) · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• Y02P10/25

  Process efficiency · CPC title

• B22F9/14 Primary

  using electric discharge · CPC title