3D Lab’s ATO Induction Melting System enables single-step alloying
March 11, 2025
3D Lab sp zoo, based in Warsaw, Poland, recently highlighted the use of its ATO Induction Melting System (IMS) – an optional module intended to enhance the company’s ATO ultrasonic metal atomisers – to design and manufacture metal powders in a single-step process.
By adding the IMS module, materials can be melted at temperatures of up to 1700°C, enabling advanced material processing and alloy development. The module is also said to be highly effective when atomising materials with low melting points (e.g., copper and aluminium). 3D Lab’s ATO process is also said to prevent element evaporation during atomisation, enabling the stability of the alloy’s chemical composition.
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Two operational modes
IMS offers two operational modes: crucible and rod.
The crucible configuration allows melting and atomisation of feedstock in various forms, including chips, powders, pellets, and irregularly shaped materials, making it well-suited to material recycling and sustainable manufacturing.
Each crucible has a hole drilled in it that is not closed during the entire process, thus eliminating the possibility of contamination of the material via the plug. The material is then dosed from the crucible onto the atomisation platform using the pressure difference.
The rod version minimises contamination risk by eliminating contact with crucible materials, enabling the production of a high-purity powder suitable for demanding applications (e.g. in the medical industry.)
Alloying
In addition to processing conventional materials, IMS enables the development of alloys via a single-step process combining preparation, melting, and atomisation. This technology is said to result in powders with good sphericity and controlled particle size distribution (PSD), allowing users to produce different powder sizes suitable for various Additive Manufacturing technologies and applications.
An example highlighted by 3D Labs is the recent development of high-entropy aluminium using its IMS technology. The process went as follows:
- Pure aluminium, iron, chromium and niobium were loaded
- The aforementioned pure elements were melted and fully homogenised via stirring and argon gas
- Molten metal was poured onto the atomisation via a pressure differential
- Ultrasonic atomisation converted the molten material into fine powder
When the resultant HE aluminium alloy was analysed via SEM-EDS, the company reported its precise chemical composition, ideal sphericity and narrow particle size distribution, making it well-suited to Additive Manufacturing and other advanced metallurgy technologies.
