Ultrasonic Atomization of Novel Materials for Aerospace Applications

Current methods for the production of spherical powders restrict the development of custom particles with tailored chemical composition. Ultrasonic atomization process enables in-house powder production from even 1 gram up to a few kilograms of new metallic materials in single process. Technology use the vibrations to eject the particles from liquid metal. To melt the material plasma torch or induction heating can be applied allowing to process wide range of metals. Plasma-based ultrasonic atomization was used to manufacture spherical powder of the high-temperature alloy for jet engine applications, while induction-based ultrasonic atomization was utilized to develop a low-melting alloy.

Ultrasonic atomization allow production of small batches of powders with tailored chemical composition which is crucial for alloy development in powder-based methods, like additive manufacturing [1]. High-temperature alloy was based on niobium - the lightest among the refractory metals, specifically C103 alloy which for the first time was used in the nozzle-extended segment of the Apollo manned lunar module rocket engine in 1965. Obtained powder features high sphericity and uniform distribution of elements, but most importantly without HfO2 formation. Case study concerning a molybdenum - rhenium binary alloy will be presented for which annihilation of oxygen pickup is crucial and is used in military high-temperature applications. Low-melting alloy obtained via induction-based ultrasonic atomiziation was novel aluminium alloy for structural applications, like satellites requiring high-stiffness and low mass which can be achieved by laser pwoder bed fusion and topology optimization.


__________________________________________________________________________________________________________
Biography

Jakub Ciftci is a material researcher focused on developing new alloys for additive manufacturing obtained through ultrasonic atomization in the Warsaw University of Technology spin-off company - AMAZEMET. Currently, an application engineer at AMAZEMET enhancing the company's product offerings and solutions. Jakub is pursuing Ph.D. at Warsaw University of Technology, actively seeking research partners for collaborative R&D projects. This dual role highlights his commitment to both academic excellence and industry innovation. Specialized in the development of process parameters for laser powder bed fusion to tailor the obtained microstructures. Recent research concerns alloys for high-temperature applications including refractory alloys and circular economy in additive manufacturing by recycling the materials by laboratory-scale ultrasonic atomizer. This approach not only enhances sustainability but also maximizes the efficiency of material usage in manufacturing processes.