Powder2Powder Atomization System Upcycles Powder Waste and Enables Custom Powder Production for Additive Manufacturing

Amazemet (Warsaw, Poland) has developed a Powder2Powder (P2P) atomization system that offers a solution for recycling metal powders and manufacturing custom pre-alloy powders directly from powder feedstock. 

The technology combines plasma processing and ultrasonic atomization to transform irregular or oversized particles into highly spherical, satellite-free powders optimized for additive manufacturing (AM). Unlike plasma spheroidization, the P2P technology enables powder size to be independent of the initial feedstock, making it the only technology capable of direct atomization of pulverized Ti-feedstock.

The company says that extensive trials using over 200 µm oversize and irregular Ti alloy powders have shown exceptional results with the P2P system. Operating at a frequency of 40 kHz, the system consistently achieved a powder morphology with an aspect ratio (D50) exceeding 0.95. The particle size distribution (PSD) was precisely controlled, producing powders with D90 < 80 µm and yielding particles <63 µm at ≥80%.

Nearly 97% of the resulting powder was suitable for AM processes, including laser powder bed fusion (LPBF), directed energy deposition (DED) and electron beam melting (EBM), highlighting the system’s potential to enhance sustainability in metal powder production. 

The P2P system can also process blends of elemental powders, creating pre-alloyed materials tailored to exact chemical compositions. This capability makes it invaluable for both research and industrial applications.

Tests conducted with Ti and 10% wt. Mo elemental powders showed that both refractory elements formed homogeneous alloy powders during processing. Set for release in Q1 2025, this patented technology addresses two critical challenges in the AM industry — upcycling of powder waste and custom powder production — delivering advanced functionality that surpasses traditional recycling methods.

Key Features:

• Particle Size Distribution Control: The system adjusts the particle size distribution (PSD), transforming undersized and oversized particles into powder optimized for LPBF, DED and other AM techniques.
• Powder Morphology: By combining plasma-based technology for melting feedstock powders with ultrasonic atomization to refine particle morphology, the system transforms irregular powders into highly spherical, satellite-free particles, thereby enhancing performance in AM processes.
• Powder Alloying: Blends of elemental powders or commercial alloys with minor alloying element additions can be used as feedstock for atomization. Unlike in EIGA or plasma atomization, new alloys can be rapidly developed without preprocessing, electrode casting or wire drawing.
• Multimaterial Capability: The system handles a wide range of metal powders, including steel, titanium, nickel, refractory alloys and high-entropy alloys (HEAs), with the ability to create powders that meet specific AM feedstock requirements.
• Sustainability and Efficiency: By converting otherwise unusable powders into AM-ready material, the P2P system minimizes waste and supports sustainable manufacturing practices.

“The Powder2Powder system goes beyond recycling,” says Łukasz Żrodowski, Amazemet inventor and CEO. “It gives manufacturers the ability to customize powder compositions, improve powder sphericity and optimize particle size distribution, solving critical issues in the AM industry. We’re excited to debut this at Formnext 2024, where we’ll showcase how it can enhance the efficiency and sustainability of powder-based manufacturing.”