For more information please visit our website: www.vtt.fi/powder. We are material experts specialized on powder based materials. With Powder Piloting Service we can boost up your development needs and adoption of resource efficient manufacturing and alternative materials for substitution.

1. Powder Piloting Service
Material solutions, from powder to product.
VTT Technical Research Centre of Finland Ltd
Facilities
www.vtt.fi/powder

2. Post treatments
& characterization
Powder
Consolidation
www.vtt.fi/powder
 Gas Atomisation
 Spray drying
 Plasma spheroidization
 Mechanical Alloying &
Mixing
 Powder Classification
 Additive Manufacturing (AM)
 Hot Isostatic Pressing (HIP)
 Powder Injection Molding (PIM)
 Self-Propagating High
Temperature Synthesis (SHS)
 Thermal Spraying
 Laser Cladding
 Heat treatments
 Surface Treatments
 Performance Testing &
Validation
 Powder Characterization
Powder
manufacturing

3. Phenomena and affecting parameters
 Multiscale material modelling
ProperTuneTM
 Materials
 Processes
 Characterisation
 Performance
Powder development and production
 Metals, ceramics polymers and
composites
 Milling systems
 Gas atomisation
 Plasma spheroidization
 Spray drying
 Post treatments
Consolidation
 Thermal spraying (TS)
 Hot Isostatic Pressing (HIP)
 Powder Injection Molding (PIM)
 Reactive synthesis
 Additive manufacturing
Performance
 Materials in service environments
 Degradation mechanisms
 Lifetime evaluation
Core competences in powder technology in VTT
Material efficiency via tailored material and production routes
www.vtt.fi/powder

4. POST TREATMENTS - THERMAL - CHEMICAL - CLASSIFICATION
CERAMIC - COMPOSITE - INTERMETALLIC - AMORPHOUS - METAL ALLOYS
CATALYST - THERMAL SPRAY - CLADDINGS - MIM - HIP - LASER SINTERING -
CASTINGS - POLYMER COMPOSITES
WET & DRY MILLINGSPRAY DRYING FLUIDIZED BED MIXING
CHEMICAL SYNTHESIS MECHANO-CHEMICAL SYNTHESIS GAS ATOMIZATION
Pilot scale routes for powder processing
www.vtt.fi/powder

5. Powder
manufacturing
www.vtt.fi/powder

6.  Gas atomization
 Metal powders
 Spray drying
 Ceramic and composite powders
 Optimization of slurry properties
 Homogeneous dispersions
 Induction plasma reactor
 Spheroidization
 Synthesis
 Purification
 Different milling systems:
 Mechanical alloying
 Raw material modification e.g. grinding fuse and crush powders
 SHS-combustion
 Composites, intermetallics
 Chemical synthesisDifferent milling systems:
 Mechanical alloying
 Raw material mod. e.g. grinding
 Granulation and coating of powders
www.vtt.fi/powder
Powder processing equipment

7.  5 kg steel (2 kg Al)
 Max. temperature 1750°C
 Inert gas atomisation vacuumed/over
pressure
 Particle median size 10-100 µm
adjustable: atomisation pressure,
metal throughput rate, viscosity,
surface energy
 Cyclone separates fines 85 % 1 µm
 Cooling rate max. 105-106 Ks -1
Atomisation equipment
www.vtt.fi/powder

8. Atomisation
 Gas atomised powders
 Both powder metallurgical and thermal
spraying
 HIP, SPS, Laser, Conventional sintering,
Microwave
 HVOF, Plasma
 Tailored material compositions
 Gas atomised powders are spherical
 Inert gas atomisation, Ar or N2
 High purity
 Particle size 2-100 µm
 Fines can be removed by air classification,
coarse by sieving
 Flowability and filling characteristics are good
www.vtt.fi/powder

9. 922/12/2017
 TEKSPHERO-15
 15 kW induction plasma system for powder
spheroidization and purification
 Semi continuous approx. 5 liters batch size
www.vtt.fi/powder
 Improved powder flowing properties
 Spheroidized particles provide a more
homogeneous and stable flow while
feeding.
 Decreased powder porosity
 Porosity is removed when the material
is melted.
 The tap density of the powder is
increased
 Decreased powder friability
 The treatment removes internal
fractures or weak internal bonds and its
end effect is a longer life for the parts.
 Enhanced powder purity
 Enhance powder purity through the
selective/reactive vaporization of
impurities. The purity of the initial
material by a factor of 10 to 100.
Plasma spheroidization

10. Spray drying
 In spray drying, water or alcohol based slurry is
introduced into a spray drying chamber through a
special atomization nozzle. In the hot gas flow and
spherical granulates are formed.
 Ceramic and cermet powders for thermal spraying
and compaction with different particle size
fractions
Niro Spray Dryer P-6.3, pilot scale
 Rotation atomizer
 Particle size range: ~5-70 µm
 Drying gas: air
 Drying capacity: ~10 l/h
Buchi Spray Dryer B-290, laboratory scale
 Two-fluid atomizer
 Particle size range: ~1-40 µm
 Drying gas: air, N2
 Drying capasity: ~0,5 l/h​
www.vtt.fi/powder

11. Fluidized bed Aeromatic MP-1
Fluidized bed can be used for drying, granulation,
coating and encapsulating of powders and powder
mixtures.
 Bach sizes 0,35-6 kg differencing from material
 Max. temperature 80°C (plexus cyclone)
 Gas velocity 0,4-1,8 m/s
 Sieves can be changed according to particle size
 Liquid can be feeded both upwards and downwards
 Larger granule size than with spray dryer
 Closed loop processing by modification of the equipment
 Can be scaled up and simulate continuous processes
www.vtt.fi/powder

12. 22/12/2017 12
Indutherm VTC800V
 Temperature: 2000°C, temperature read by a optical pyrometer
(plus thermocouple up to 1300°C)
 Ceramic crucible capacity: total 800 cm³
 Flask’s size and Ingot moulds up to maximum ø125 x 220 mm
 Automatic running for repeatable results
 Melting modes: under higher vacuum, standard atmosphere
(inert gas protection) or inert gas overpressure
 Induction generator with 20 kW heating power, direct controlling
of power
 Low frequency induction = excellent mixing of liquid metal
 After casting: automatic overpressure routine
 Vibration technology ensures casting with excellent form filling,
best metal density and top metal microstructure
www.vtt.fi/powder
Vacuum casting machine

13. Synthesis of Inorganic Particles
Initial phase  synthesis  product
Chemical synthesis is intentional chemical
reaction to produce new material compositions
or coated particles.
Examples of result
 Silanization of particles
 Oxide particles with SOL-GEL
 Nano carbides
 Catalys synthesis
Description of facility
 Mixing equipment
 Controlled atmosphere furnaces
www.vtt.fi/powder

14. Mechanical milling and alloying
 Circulating agitated ball mill
 Different type and size of ball mills
 Attritor, planetary, vibrating and conventional ball mils
 Wet and dry milling
 Mixing, alloying, coating, shape modification, grinding,
dispersing etc.
 50 ml to 20 l vial sizes
 Vials and milling media; steel, hard metal, ceramic,
rubber
 Atmosphere; air, protective gas or reactive gas
such as H2
www.vtt.fi/powder
Agitated Lab Ball Mill 90 AHM

15. 22/12/2017 15
Powder Sieving and Classification
Hoskawa Alpine
 Air classification with integrated jet mill and
hammer mill
 Capacity 1 – 100kg
 Separation of fines
 Grinding of brittle materials
Laboratory sieves
 Sieving, laboratory Analysette
 25, 32, 45, 63, 90, 125, 250, 500, 1000
µm
 High productivity Douple Shaker sieve
system
 Continuous high productivity sieving system,
capacity with metal powders ~10kg/h
www.vtt.fi/powder

16. Powder
consolidation
www.vtt.fi/powder

17. 22/12/2017 17
Additive Manufacturing
Selective Laser Melting
SLM Solutions SLM 125 HL
 Chamber size: 125x125x125 mm
 Could be decreased 60x60x60 mm
 Laser source: 400W IR fibre laser
 Inert gas Ar or N2
 Fully controllable process parameters
 Suitable for the most of metal alloys
www.vtt.fi/powder

18. Powder consolidation facilitiesHot Isostatic Pressing (HIP)
HIP opportunities:
 Special PM-Alloys, ceramics and MMCs
 Bulk components and thick coatings with high
wear and corrosion resistance
 Near net shape components with internal
structures and channels
Example of result:
 Steels and super alloys reinforced with oxide,
nitride and carbide particles
 Copper-steel compoud structure for ITER
reactor wall
 Optimized cooled plastic mold
 High nitrogen steel from gas nitrided AISI 316
powder 5,7 % N (micrograph left)
Description of HIP:
 Chamber dimensions ø 130x300 mm
 Tmax 1450°C or 2000°C
 Pressure 207 Mpa (2070 bar), argon
 Dilatometry for densification study www.vtt.fi/powder

19. Powder Injection Molding (PIM)
PIM opportunities:
 Prototypes and process design
 Small complicated 3D-parts from conventional and high
strenght wear resistant materials
 Materials: stainless steel, carbon steel, copper, titanium
and ceramics
Example of result
 Complicated components at costs of 50 % lower
PIM facilities
 Injection Molding machine Arburg 60 tn
 Thermal, solvent and water de-binding
 Sintering in high vacuum molybdenum furnace up to
1360°C or in low vacuum graphite furnace up to 2000°C
 Post-treatments of steel components
www.vtt.fi/powder

20. Thermal spray and coating facilities
 Coating manufacturing processes
 Plasma spraying
 HVOF
 HVAF
 Cold spraying
 Arc spraying
 Powder and wire flame spraying
 Polymer flame spraying
 Laser cladding
 CMD cladding
www.vtt.fi/powderwww.tscf.fi

21. Post treatments
& characterization
www.vtt.fi/powder

22. 22/12/2017 22
TORVAC Compact 30 Model 1218, vacuum
furnace
(Cambridge Vacuum Engineering Ltd.)
 Max. Temperature 1350°C
 Possibility to gas quenching
 Effective chamber size 200(L) x 400(W) x
200(H) mm
 Batch size max. 60 kg
 Molybdenum resistors, no carbon
contamination
 Atmospheres
 Vacuum ~10-5 mbar
 Argon 50 mbar
www.vtt.fi/powder
High temperature furnaces

23. 22/12/2017 23
VERTIVAC 150/2200 high temperature furnace
 Effective size; dimeter 150 mm , height 160 mm
 Max temperature 2200 °C, with thermocouples
650 °C, pyrometer T>1650 °C
 Graphite resistors
 Atmospheres
 Vacuum 5*10-2 mbar
 Argon , Nitrogen or another inert gas with pressure
range 50 mbar - 1500 mbar
 Argon-Hydrogen mixture gases
 Cold box before vacuum pump enabling de-
binding
 Possibility for example reactive sintering with
controllable atmosphere 2,5 - 1500 mbar with gas
flow 0 - 30 l/h
www.vtt.fi/powder
High temperature furnaces

24. 22/12/2017 24
SARLIN LP25 fluidized bed furnace 200/400
 Effective size: diameter 200 mm, height 400
mm
 Max. temperature 1080 °C
 Fluidized alumina bed provides
homogeneous temperature, high thermal
transfer and effective gas reactions
 Atmospheres
 Air
 Inners gases: Argon, Nitrogen
 Ammonia for nitriding
 Hydrogen mixture gases
 Propane-air mixture for carburization
www.vtt.fi/powder
High temperature furnaces

25. 22/12/2017 25
Rotary tube furnace
 Variable tilting angle
 Changeable tube
 Maximum temperature 1550°C
(1450°C in continuous use)
 Variable gas atmosphere (air,
N2, Ar, H2)
 Gas tight 5l feeding
 Collecting system
Rotary furnace with reactive atmosphere
www.vtt.fi/powder

26. Characterization
 Particle size
 Malvern mastersizer
 Malvern nanosizer/zetasizer
 Flowability, apparent density
 Hall flow meter
 Avalance angle
 SEM/EDX
 EDX mapping
 Optical microscopy
 XRD
 High resolution detector
 Small angle
 Thermal analysis
 Integrated TG/DSC/MS
 Thermal conductivity
www.vtt.fi/powder

27. Equipment for measuring particle size distributions for both
wet and dry dispersions.
General
 Principle: laser light scattering
 Measurement media: Liquid (water, ethanol), Air
 Size range: wet 0,01-3500 µm; dry 0,1-3500 µm
 Dispersion: wet ultrasonic; dry air pressure
Optics
 Red light source: Max. 4mW He-Ne, 632,8nm Blue light source:
Max. 10mW LED, 470nm
Detector
 Angular range: 0,015-144 degrees
www.vtt.fi/powder
Particle size distribution
Laser diffractometer: Master sizer 3000 (Malvern)
Measurement unit
AERO S for dry measurements
HYDRO LV for wet measurements

28. 2822/12/2017
Thermal analysis
Simultaneous Thermogravimetry (TGA), Differential
Scanning Calorimetry (DSC) and Mass Spectrometry (MS)
STA 449 F1 Jupiter r
 Temperature range: RT to 1500°C (Platinum furnace)
 Weighing range: 5000 mg (depends on size of crusible, in this
model ~20 µl)
 TGA resolution: 0,025 µg
 DSC resolution < 1 µW (dependent on sensor)
 Atmospheres: inert, oxidizing, reducing, static, dynamic,
vacuum
 Auto sampler
QMS 403 D Aëolos mass spectrometry
 Temperature range RT-1600°C
 Mass Range 1 to 300 u*
 Resolution 0.5 u*
www.vtt.fi/powder

29. Zetasizer Nano ZS
Equipment for measuring particle size, molecular
size, zeta potential and molecular weight as function
of pH
Measurement type: Particle size and molecular size
 Measurement range: 0,3 nm-10,0 µm
 Measurement principle: Dynamic Laser Light
Scattering
Measurement type: Zeta potential
 Measurement range: 3,8 nm-100 µm particle size
 Measurement principle: Electrophoretic Laser
Light Scattering, Brownian motion
Measurement type: Molecular weight Measurement
 Range 980 Da-20 Mda (g/mol)
 Measurement principle: Static Laser Light
Scattering using Debye plot
Reference: Malvern website www.vtt.fi/powder
Measurement unit
Autotitrator

30. XRD
 XRD, X-ray diffraction
 High resolution detector
 Small angle measurements
 Determination of the crystal structure
 Phase determination
 Crystallinity
 Easy conversion to transmission
geometry
 Measurement of thickness and quality
of thin film structures
 Measurement of nano-sized structures
www.vtt.fi/powder

31. For more information
please visit our website.
www.vtt.fi/powder
Interested?
VTT Technical Research Centre of Finland Ltd