AMAZEMET, an innovator in metal power production is set to introduce its new Powder2Powder (P2P) atomisation system at Formnext 2024. The P2P system presents a versatile solution for recycling metal powders and manufacturing custom pre-alloy powders directly from powder feedstock.
This unique technology (Figure 1) combines plasma processing and ultrasonic atomisation to transform irregular or oversized particles into highly spherical, satellite-free powders optimised for additive manufacturing (AM). Unlike plasma spheroidisation, the P2P technology allows powder size to be independent of the initial feedstock, making it the only technology capable of direct atomisation of pulverised Ti-feedstock.
Extensive trials using +200 μm oversize and irregular Ti alloy powders have shown exceptional results with the P2P system. Operating at a frequency of 40 kHz, the system consistently achieved a powder morphology with an aspect ratio (D50) exceeding 0.95. The particle size distribution (PSD) was precisely controlled, producing powders with D90 < 80 μm and yielding particles <63 μm at ≥80%. Nearly 97% of the resulting powder was suitable for AM processes, including Laser Powder Bed Fusion (LPBF), Directed Energy Deposition (DED), and Electron Beam Melting (EBM), highlighting the system’s potential to enhance sustainability in metal powder production.
of pure Ti and Mo elements, b) as atomized TiMo alloy, c) Particle Size Distribution of feedstock
and TiMo alloy, d) sphericity of feedstock and TiMo alloy
Additionally, the P2P system can process blends of elemental powders, creating pre-alloyed materials tailored to exact chemical compositions. This capability makes it invaluable for both research and industrial applications. Tests conducted with Ti and 10% wt. Mo elemental powders showed that both refractory elements formed homogeneous alloy powders during processing. Set for release in Q1 2025, this patented technology addresses two critical challenges in the AM industry—upcycling of powder waste and custom powder production—delivering advanced functionality that surpasses traditional recycling methods.
Key Features:
- Particle Size Distribution Control – The system adjusts the particle size distribution (PSD), transforming under- and oversized particles into powder optimised for LPBF, DED, and other AM techniques
- Powder Morphology – By combining plasma-based technology for melting feedstock powders with ultrasonic atomisation to refine particle morphology, the system transforms irregular powders into highly spherical, satellite-free particles, enhancing performance in AM processes
- Powder Alloying – Blends of elemental powders or commercial alloys with minor alloying element additions can be used as feedstock for atomisation. Unlike in EIGA or plasma atomisation, new alloys can be rapidly developed without preprocessing, electrode casting, or wire drawing
- Multi-Material Capability – The system handles a wide range of metal powders, including steel, titanium, nickel, refractory alloys, and high-entropy alloys (HEAs), with the ability to create powders that meet specific AM feedstock requirements
- Sustainability and Efficiency – By converting otherwise unusable powders into AM-ready material, the P2P system minimises waste and supports sustainable manufacturing practices
Łukasz Żrodowski, inventor and CEO of AMAZEMET, explains, “The Powder2Powder system goes beyond recycling. It gives manufacturers the ability to customise powder compositions, improve powder sphericity, and optimise particle size distribution, solving critical issues in the AM industry. We’re excited to debut this at Formnext 2024, where we’ll showcase how it can enhance the efficiency and sustainability of powder-based manufacturing.”
Formnext 2024 attendees will be the first to experience this innovative system, which offers a complete solution for both recycling and custom alloy powder production. Learn more about how the Powder2Powder system can revolutionise your additive manufacturing processes at p2p.amazemet.com.