The following table clearly illustrates the central role and key parameters of the high-pressure plunger pump in this application:
🔧 Technical Principles and System Architecture
The basic principle of atomization-based powder production technology is to use a high-pressure plunger pump to generate a high-speed jet that breaks up, cools, and solidifies molten metal into fine powders with either spherical or irregular shapes.
The core process flow and the function of the high-pressure pump are as follows:
Melting and Flow Control: The metal is melted in an induction furnace and then flows out through a spout at the bottom of the crucible, forming a stable, slender column of molten metal.
Atomization (the core process): A high-pressure plunger pump pressurizes water to the required pressure. The pressurized water then passes through one or more carefully designed atomizing nozzles, forming a high-speed conical water curtain that intersects with the falling stream of molten metal within the atomization tower.
Breakup and Solidification: The high-speed water flow exerts tremendous shear forces on the molten metal, tearing it into countless tiny droplets. Under the influence of surface tension, these droplets tend to assume a spherical shape and, as they fall, are cooled and solidified into solid powder.
Collection and Post-processing: The powder eventually falls into a collection tank at the bottom of the atomization tower, where it undergoes subsequent processing steps—including dehydration, drying, sieving, and annealing—to yield the final product that meets the required specifications.
Why must it be a high-pressure plunger pump?
High pressure is a prerequisite for generating sufficient shear force to break up metal droplets. Generally, the higher the pressure, the finer the resulting powder.
Low Pulsation: Compared to other types of high-pressure pumps, plunger pumps—especially five-plunger pumps—deliver a smoother output pressure. Extremely low pressure pulsation is crucial for ensuring uniform fragmentation of the molten metal and producing high-quality powders with a narrow particle size distribution.
Stable and reliable: Capable of continuous, stable operation over long periods, meeting the demands of industrialized, continuous production.
📈 Performance Requirements and Equipment Selection
To meet the stringent requirements of water-based atomization for powder production, the high-pressure plunger pump system must possess the following characteristics:
Pressure and Flow Rate: The pressure range typically falls between 40 MPa and 150 MPa and is adjusted according to the target powder particle size. The flow rate, in turn, is determined based on production capacity and the flow rate of the molten metal.
Ultra-low pulsation: Employs a multi-plunger design (such as 5-plunger or 7-plunger) and is equipped with a pressure regulator or accumulator to smooth out pressure fluctuations and ensure stable atomization.
High-precision control system: Modern atomization systems typically integrate PLCs (programmable logic controllers) and frequency converters, enabling precise closed-loop control of pressure and flow rate, as well as smooth soft start/stop operations to prevent pressure surges.
Materials and Sealing: The pump body and flow-through components must be made of corrosion-resistant materials such as stainless steel, and the seals must also be compatible with high-purity water to prevent rust from contaminating the medium and ensuring the purity of the powder.
💎 Summary
In the field of water atomization powder production from metal powders, high-pressure plunger pumps have evolved from simple water supply devices into core precision units that directly influence powder particle size, morphology, oxygen content, and production efficiency. Their stable ultra-high-pressure output and precise process-control capabilities serve as an indispensable technological guarantee for producing high-quality metal powders.
