Ferrous melt Zirconia Atomising Nozzles , Molten Metal Atomization Powder Metallurgy

ZG Technical Ceramics are principle manufacturers of high performance Zirconia Atomising Nozzles for use in the Powder Metallurgy industry. Atomising nozzles are available in a wide range of shapes and sizes, many to the requirements of individual customers.

Applications include the casting and atomisation of Ferrous and Non Ferrous melts.

One of the principle features of Zirconia nozzles is their close dimensional accuracy, which promotes stable flow characteristics under the most arduous conditions. The addition of specially selected stabilising oxides provides high strength, excellent erosion resistance and minimal cracking due to thermal shock/rapid cooling.

ZG Technical Ceramics are a key manufacturer of high performance zirconia atomising nozzles. Zirconia Atomising Nozzles are used within the Powder Metallurgy industry and are a key component in the manufacturer of metal powders such as: Stainless Steel, Nickel & Colbalt based super alloys and other exotic alloys.

Powder Metallurgy

A range of ferrous and non-ferrous metals can be processed by the atomisation process. The materials can range from crude aluminium through to sophisticated super and rare earth alloys. Products formed from the process are used in a diverse range of applications, which include the automotive, aerospace, armament, electronic surface coating, pyrotechnics, paint and refractory industries.

• • This process is a method of producing powders of varying grain size for use as:
  • Bearing surface coating
  • Injection moulding
  • Sintered products – welding rods etc.
  • Photocopier inks
  • Isostatically pressed parts such as gear wheels, valve seats and magnets
  • Home, garden and leisure products

Melting is carried out in high frequency or induction type furnaces. The weight of the melt is generally small with a 200kg charge considered average and a 5-6 tonne charge very large. Cleanliness is paramount during the production process especially with the melting and atomisation of super alloys where any contamination would not be tolerated.

Iron powders can be melted by electric arc furnace or other bulk melting operation. Consequently, the melt size is larger e.g. up to 50 tonnes.

Molten metal temperatures prior to atomisation can range from 800°C (lead/aluminium alloys) to more than 2000°C (super alloy production). Process times are generally measured in minutes but new machines are being designed to operate on a more continuous basis of up to 24 hours.

The actual atomisation or conversion of the molten metal stream to powder is achieved by bombarding the stream with a high pressure jet of air, inert gas or water.

ZG Technical Ceramics – Zirconia Atomising Nozzles

• • Close dimensional accuracy for stable flow characteristics
  • Used for the water and gas atomisation of ferrous and non-ferrous metals
  • Magnesia, Yttria and Ceria stabilising oxides promote excellent erosion resistance and minimise cracking due to thermal shock
  • Extensive global references

A comprehensive range of nozzle designs have been developed to suit the specific requirements of the end user.

One of the principle features of Zirconia nozzles are their close dimensional accuracy, which promotes stable flow characteristics under the most arduous conditions.

The addition of selected stabilising oxides provides high strength, excellent erosion resistance and minimises cracking due to thermal shock / rapid cooling. These features are critical during the production of super alloys due to high specifications relating to contaminants.

1. Yttria stabilised zirconia with excellent erosion resistance properties. High temperature resistance suitable for super alloy and nickel based alloys.

2. Ceria and magnesia stabilised zirconia with excellent thermal shock resistance. Suitable for high temperature production of super alloys and nickel based alloys.

3. Zircon Nozzles

ZG manufacture a range of Zircon Atomising nozzles, mainly used in the atomisation of Iron. Zircon nozzles are ideal for shorter casting sequences or where nozzle erosion is less of an issue.

We have stock for alumina (Al2O3) and make under request, in the following materials:

• magnesia partially stabilized zirconia (Mg-PSZ),
• yttria-stabilized tetragonal zirconia (Y-TZP) zirconia
• partially stabilized with yttria (Y-PSZ),
• zirconia fully stabilized with yttria (Y-FSZ),
• zircon (ZrSiO2),
• aluminum titanate (Al2TiO5),
• mullite (Al6Si2O13)