Powder production for high temperature applications poses a challenge for manufacturers regarding feedstock production as well as the atomization process itself.

The development of lightweight high temperature materials is one of the key steps in the reduction of carbon emissions of airplanes, as they allow higher operating temperatures in jet-engines and therefore increase efficiency. Other applications include nozzle parts in stationary machines and coatings for heat shields, where low specific weight is not as important. Due to the high melting point and high strength, the materials need to be produced though a powder-metallurgical approach and products built through additive manufacturing.


For the atomization of intermetallic or brittle materials, the challenge is often the feedstock production, so that the rod of the brittle material can withstand the thermal strain in the freefall atomization process. A powder-metallurgical solution to this challenge has been implemented to overcome the challenge. An example for a successful manufacturing of high purity feedstock and consequent atomization will be given for a molybdenum based, high temperature material. [1]

For high melting, ductile materials such as refractory metals, a set of parameters could be found to produce fine, spherical, flowable powders from Mo-W feedstock, with a melting point of  ~2770 °C. Challenges included the high viscosity of the melt, due to the high melting point of the material and the limited possibility to superheat the material in a free fall atomization process. [2]


References
[1]     F. Hinrichs, et. al.; Metals 2021, 11.11, 1723.
[2]    S. Spitans, et. Al.; Conference paper: 11th PAMIR international Conference – Fundamental and Applied
MHD 01-05/07/2019, Reims, France 2019.