Alloy Prototyping in AM using the flexebility of ultrasonic atomization

Advances in additive manufacturing (AM) have highlighted the growing need for a wider range of metal alloys in powder form. Traditional atomization techniques, such as gas, plasma, and centrifugal methods, though capable of producing high-purity spherical powders, are limited by high material input requirements, expensive equipment, and compatibility with a narrow range of materials. This creates a bottleneck in material diversity, particularly when small quantities are required for prototyping, research, or unit manufacturing.

Ultrasonic atomization offers a compelling solution by addressing these limitations, enabling the production of tailored powders with minimal material input. Unlike large-scale methods, ultrasonic atomization is particularly suitable for laboratory-scale production, allowing for rapid validation of novel alloy compositions, phase structures, and mechanical properties. A plasma processing module with a crucible-free process minimizes contamination risks, making it ideal for handling materials such as Titanium, Nickel, and Refractory materials commonly used in aerospace applications. An induction melting module for Mg and Al can be used to precisely control the temperature when processing low melting point materials to minimize the risk of evaporation.

This presentation will explore ultrasonic atomization in a series of case studies with custom Mg, Al, Ti, and HEA alloys as a versatile and cost-effective alternative, showcasing its capability to produce small batches of reactive and exotic materials for 3D printing and other advanced manufacturing techniques. By overcoming the material and cost limitations of conventional methods, ultrasonic atomization enables researchers and manufacturers to expedite alloy development and explore new material possibilities in a more accessible, scalable manner.