Continuum Powders is transforming metal scrap into ASTM-grade powders
November 13, 2024
Continuum Powders, based in Los Gatos, California, USA, has shared an article addressing supply chain challenges and environmental issues through ‘scrap’ metal reuse. By transforming existing metal parts into high-quality powders, Continuum Powders can create a sustainable, cost-effective solution that meets the high standards of ASTM-grade materials.
The challenges of traditional metal powder supply chains
Traditional metal powder supply chains heavily depend on the extraction and processing of virgin metals. This dependence carries substantial environmental and economic costs. Mining for raw materials is energy-intensive and contributes to carbon emissions, habitat destruction, and other types of environmental degradation. Additionally, the price of virgin metals fluctuates due to market volatility, which can affect the financial stability of manufacturing operations.
In this context, adopting a circular economy model presents a promising alternative. A circular economy emphasises minimising waste and maximising the use of resources for as long as possible. By reclaiming and repurposing metal waste, manufacturers can reduce their reliance on newly extracted materials, decrease their environmental impact, and create a more resilient supply chain.
The process of reclaiming metal scrap
Reclaiming metal scrap into ASTM-grade powder involves several critical steps, each designed to ensure the final product meets stringent quality standards:
- Collection and sorting: The process begins with collecting metal scrap, which is then sorted based on material type and alloy composition. Proper sorting is crucial to maintain the quality and performance of the final powder.
- Cleaning and processing: The sorted metal scrap undergoes cleaning to remove any impurities, such as oil, dirt, and other contaminants. This step ensures that the final powder is free of impurities that could compromise its properties.
- Size reduction: The cleaned metal is then subjected to size reduction, typically through shredding or milling. This step prepares the material for atomisation by breaking it down into smaller, more manageable pieces.
- Atomisation: During atomisation, the metal is melted and then converted into powder by spraying it through a nozzle using gas or water. This process produces fine, uniform particles that are essential for advanced manufacturing applications.
- Quality control and testing: Finally, the reclaimed powder undergoes rigorous quality control and testing to ensure it meets ASTM-grade specifications. Advanced technology and expertise are essential in this phase to guarantee that the reclaimed powder performs at the same level as, or even better than, virgin material.
Continuum Powders’ approach to powder lifecycle management
Continuum Powders offers a powder management solution designed to maximise both efficiency and sustainability. Its technologies and sustainable practices ensure that reclaimed powders meet or exceed industry standards.
The proprietary Greyhound M2P platform is transforming the metal additive manufacturing industry by converting reclaimed metal into high-quality Continuum OptiPowders. This process guarantees that the resulting powders meet the stringent standards required for advanced manufacturing applications, including Laser Beam Powder Bed Fusion (PBF-LB), Electron Beam Powder Bed Fusion (PBF-EB), and Binder Jetting.
Continuum Powders sources metal from industries such as aerospace, automotive, and electronics. It implements stringent quality control measures throughout the entire process. The waste is meticulously prepared and sorted to ensure consistency in both quality and composition.
Next, the prepared metal waste is melted in melted in a high-temperature furnace and then atomised, creating tiny, spherical powder particles. This atomisation process is essential for producing powders with the ideal characteristics for Additive Manufacturing.
The metal powder undergoes rigorous testing to assess its particle size distribution, flowability, and chemical composition. By maintaining the highest standards, the company ensures that its Continuum OptiPowders are appropriate for demanding AM applications.
Continuum Powder’s Greyhound M2P technology demonstrates the company’s commitment to sustainability and circular economy practices. By converting previously used or discarded metal into valuable resources, Continuum Powders plays a significant role in creating a more environmentally friendly and efficient metal Additive Manufacturing industry.
Continuum Powders’ process at a glance
- Greyhound Melt-to-Powder (M2P) technology: Its proprietary technology converts used metal alloys into high-quality powders in a single step, maintaining optimal particle size and shape for AM applications.
- Certified reclaimed powders: Continuum Powders ensures all reclaimed powders are ASTM-grade. Matching or surpassing the quality of virgin materials for demanding applications like PBF-LB.
- Lifecycle management services: Continuum Powders assists with powder collection, re-atomisation, and reprocessing to extend the lifecycle of materials.
- Technical support: The Continuum Powders team provides expertise to help customers optimise powder performance throughout production.
Continuum Powders adopts a comprehensive approach to ensure that each stage of the powder lifecycle not only enhances operational efficiency but also furthers environmental objectives.
Benefits of using reclaimed metal powder
Reclaiming metal scrap has been shown to significantly reduce the environmental impact associated with traditional metal powder production. By minimising waste and lowering the need for new mining activities, reclaimed metal powders contribute to a more sustainable manufacturing ecosystem. This approach also supports a circular economy, where materials are kept in use and their lifecycle is extended, ultimately reducing the overall demand for raw resources.
Reclaimed metal powders can be produced at a lower cost than virgin materials. The decreased need for raw material extraction and processing leads to cost savings that can be passed on to manufacturers. Furthermore, using reclaimed powders can offer long-term savings by establishing a more stable and predictable supply chain.
Continuum Powders’ advanced processing techniques reportedly ensure that reclaimed powders offer the same strength, ductility, and impact resistance as virgin metals.
The consistency and reliability of reclaimed metal powders make them a viable source for advanced manufacturing. By utilising processing technologies and implementing strict quality control measures, Continuum Powders ensures that each batch of reclaimed powder provides consistent results, helping manufacturers uphold high standards of quality.
Reclaimed metal powder offers a sustainable, cost-effective, and high-quality alternative for advanced manufacturing. By reducing environmental impact, supporting a circular economy, and providing reliable, ASTM-grade materials, reclaimed powders present a compelling solution for the future of the metal powder industry.
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