Melting and ultrasonic atomisation system - rePowder System (AMAZEMET)

With the rePowder System from AMAZEMET, we have a state-of-the-art Melting and ultrasonic atomisation system which enables the flexible production of metal powders on a laboratory and pilot scale. The system supports both the development of new alloys and the reproducible production of powders for additive manufacturing, powder metallurgy and basic research into materials technology.

Function and technology

In the rePowder process, the starting material is melted and then broken down into fine droplets using a high-frequency sonotrode, which solidify in inert conditions to form almost spherical powder particles. Depending on the desired particle size, two Excitation frequencies available:

• 20 kHz - for powders that tend to be coarser, suitable for DED or EBM applications
• 40 kHz - for finer powders, ideal for LPBF, classic sintering processes and thermal coating processes

The system thus enables the powder characteristics to be specifically adapted to the respective production process.

Modular melting systems

The system is equipped with two melting modules for maximum material diversity:

• Crucible module (induction melting)
  For low to medium-melting metals and alloys such as aluminium and copper alloys. The process offers high material homogeneity and stable melting conditions.
• Plasma/Arc module
  For refractory, reactive or difficult-to-process materials. This module enables the reliable processing of titanium, nickel and iron-based alloys as well as refractory metals.

The modules can be changed quickly and adapted to different material systems.

Wire and rod atomisation

In addition to the melting down of solid materials, the system also allows the Continuous atomisation of wire or rod material . This is particularly advantageous for high-performance alloys or powder synthesis with defined chemistry. Automated feeding ensures reproducible process conditions and longer, stable melting phases.

Powder quality and research use

The ultrasonic atomisation process produces powder with:

• high sphericity
• narrow particle size distribution
• Very good flow properties
• high purity due to inert gas processing

This makes the system ideal for research work on new alloys, recycling concepts, powder properties or process optimisation in additive manufacturing.

Possible applications for partners and industry

We offer research and development co-operations in the following areas:

• Development and testing of new alloys
• Production of customised small quantities of metallic powder
• Investigation of powder parameters for AM processes
• Recycling of residual powders or metallic rejects
• Process studies on ultrasonic atomisation and enamel mechanisms