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ATO Lab Plus Atomizer

Compact ATO Lab Plus Atomizer is an innovative solution for high quality metal powders production using ultrasonic atomization method.

ATO Lab Plus brochure
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Details

Brand

Country of origin

Poland

Process

Metal powders production

Technology

Ultrasonic atomization

Meltimg method

TIG

Sonotrode type

Half-wave nanoalloy sonotrode – patent pending

Inert gas flushing method

Vacuum pump

Cooling method

Liquid

Processable materials

Non-reactive & reactive alloys (e.g. Ti, Al., Zr alloys, intermetallics e.g. Zr-based bulk metalic glass TiAl, NiAl, NiTi) and other refractory metals

Powder quality

Low oxygen content, Narrow PSD, High flowability, Spherical particle shape

PSD (particle size distribution)

20-120um

Powder collecting system

Cyclone

Protective atmosphere preparation time

<5 min.

Input material

Wire / rod (upgrade: SingleBoltFS)*

Certification

CE

Ultrasonic frequency

35 kHz (+ upgrade to higher frequency)

O2 level

< 150 ppm

System throughput

up to 0,3l/h

Machine weight

600 kg.

Size (WxDxH)

1994x813x1138 mm

Air supply

Compress air station

Inert gas

Argon

Power supply requirements / consumption

400V, 20KVA / 3 phase

Cleaning unit

Ultrasonic cleaner

Powder recycling system

Sieving unit

Water cooling

External chiller

Guarantee

12 months

Description

ATO LAB Plus is a unique compact machine for metal powders production using the latest ultrasonic atomization technology. This revolutionary solution enables the rapid production of metal powders with a narrow particle size distribution. ATO LAB Plus can produce several hundred grams of metal powder per hour with particle sizes ranging from 20 to 120 microns.  The hermetically sealed process chamber allows the production of powders of reactive metals and their alloys such as titanium or aluminum. The production is based on ultrasonic atomization technology. In this way powders can be produced with almost any particle size limitation. The ATO LAB Plus has compact dimensions, which allow it to be used efficiently even in small research laboratories. The ATO LAB Plus is no larger than an ordinary office cupboard. ATO LAB Plus is equipped with specialized, versatile and user-friendly software, and the operator can control the process from the touch screen display. The main objective was to create a system that can be used even by a novice. The new MBRFS module provides greater efficiency with a multiple bar feed mechanism, an automatic magazine feeder for the use of multiple bars n a single atomization process.

 

REACTIVE AND NON-REACTIVE METALS

ATO LAB Plus can produce several hundred grams of metal powder per hour with particle sizes from 20 to 120 microns.  The hermetically sealed process chamber allows the production of powders of reactive metals and their alloys such as: titanium or aluminum.

LOW WASTE

ATO LAB atomizer is a new way of creating high quality metal powders. This method is based on a special technology that was developed for universities, research departments and service bureaus. However, due to their reliability and efficiency, these atomizers have also found applications in industry.

 

OPEN ATOMIZATION PARAMETERS

ATO Lab Plus is specifically designed to eliminate the limitations of automation. The device has a compact size, so it can be used even in confined spaces. It is equipped with innovative technology and does not require complex infrastructure, thus reducing operating costs and providing a quick return on investment.

ULTRASONIC POWDER ATOMIZATION TECHNOLOGY

Ultrasonic vibration technology is used to break molten metal into small droplets, which rapidly solidify into metal powder in an inert gas atmosphere. The metal powder size produced depends on the frequency of the ultrasonic waves, with higher frequencies producing smaller particles and lower frequencies producing larger particles. Factors affecting particle size and distribution are viscosity, density, ultrasonic amplitude and atomizer design. Ultrasonic atomization of metal powder using ATO technology is a process in which metal powder is melted using an electric arc. Ultrasonic vibrations are then transmitted into the molten metal, creating capillary waves. These waves eject metal droplets, which are rounded and cooled before being collected and sorted. The result is almost perfectly spherical metal droplets.

AlSi7Mg Aluminium Metal Powder
AlSi10Mg Aluminium Metal Powder
Al-Mg Aluminium Metal Powder


METAL POWDER MAIN APPLICATIONS

The resulting metal powders are used for 3D printers using Laser Powder Bed Fusion (LPBF) technology, also known as Selective Laser Melting (SLM). This is a metal 3D printing technology that uses a high-powered laser to selectively melt and sinter metal powder particles together to create a solid part. In this technology, a layer of metal powder with a standard particle distribution of 10-60 microns is applied to the working platform. A powerful laser is then used to selectively melt and sinter the powder particles together, layer by layer, until the part is complete. The process is performed in a controlled atmosphere to prevent oxidation and ensure high quality parts are produced. LPBF/SLM is used in a variety of industries including aviation, automotive, medical and industrial manufacturing. It is especially useful in applications that require high strength and high temperature resistant parts with complex geometries. Another area of application is Direct Energy Deposition technology. DED is a 3D printing technology that uses a high-energy source such as a laser or electron beam to melt and deposit metal powders or wires onto a substrate. This technology is capable of producing metal parts with high strength, high density and complex geometries. DED is used in various industries such as repair and maintenance to refurbish damaged turbine blades or engine parts.


ATO LAB PLUS ADVANTAGES

Compact size, suitable for use in small spaces

With its dimensions of 78×42×60in / 200x107x154cm, weight of 1543lbs / 700kg and equipped with roller wheels it is quite mobile and easy to transport.

Innovative technology to ensure efficient operation

ATO Lab Plus is a new device that creates high-quality metal powders for use in 3D printing. It can produce various types of metal powders, including aluminum, copper, stainless steel, titanium, and other alloys.

Low operating costs and quick investment return

ATO Lab Plus is specifically designed with innovative technology and does not require complex infrastructure, thus reducing operating costs and providing a quick return on investment.


list of successfully atomized powders

Aluminum: Al 99.99%, Al5183, Al7075, AlCoCrFeNi, AlMg, AlMgCu, AlMgSc, AlSi10Mg, AlSi12/4047

Copper: Cu, CuAlNiFe, CuCrZr, CuM1E, CuMnAl, CuNi3Si, CuSn

Nickel: Inconel 625, Inconel 718, Ni, NiTi, NiTi-SE

Titanium: Ti OCT 1-90013-81, Ti-5Al-2.5Sn, TiAl, TiB2, TiMoSi, Titanium Gr.2, Titanium Gr.5 (Ti64)

Iron/Steel: 42CrMo4, AMS5832, Corfer Steel 22H, Fe 99, 5%, FeMn, ODS Eurofer, PH177 Garba, PH177 Garba Supreme, Stainless Steel 316L, Steel 304.

Refractory metals: MoSi2, Nb, Ta, W90Ni7Fe3

ATO Lab Plus is a device that can help you increase your efficiency and save money. In terms of usability, the ATO Lab Plus has an intuitive control system with a clear interface and precise parameter control. Operators can easily adjust parameters to achieve optimal powder properties for their specific needs. This ease of use makes the ATO Lab Plus ideal for research and development as well as industrial production on a large scale. The system is also equipped with a number of safety features, including a cooling water monitoring system, automatic gas shut-off valves and emergency stop buttons.