KJ GROUP GSL-1600X-VIGA300 Gas Atomization System for Metal Powder Production

Overview

The KJ GROUP GSL-1600X-VIGA300 is a laboratory-scale vacuum induction gas atomization (VIGA) system engineered for the controlled synthesis of high-purity, spherical metallic powders under inert atmosphere conditions. It integrates vacuum metallurgy, high-frequency induction melting, and high-velocity inert gas jet atomization into a single compact platform. The system operates on the principle of electromagnetic induction heating to melt feedstock alloys—such as Fe-, Ni-, Cu-, and precious-metal-based compositions—in a water-cooled copper crucible, followed by rapid disintegration of the molten stream via supersonic nitrogen or argon jets inside a sealed, ultra-high-vacuum chamber. This process yields powders with high sphericity (~1), low oxygen content (<100 ppm typical for Ni- and Fe-based alloys under optimized purging), narrow particle size distribution (d₅₀ ≤ 50 µm), and minimal satellite formation—critical attributes for additive manufacturing (AM), metal injection molding (MIM), and thermal spray applications.

Key Features

• Vacuum induction melting subsystem with 15 kW, 20–100 kHz solid-state power supply, enabling precise temperature control up to 1600 °C and stable melt pool formation.
• Integrated ultra-high-vacuum environment: base pressure <8×10⁻⁵ mbar achieved via dual-stage pumping (mechanical + diffusion pump), with verified leak-tightness (pressure rise rate <0.67 Pa/h).
• Optimized atomization nozzle design and gas delivery manifold supporting adjustable N₂/Ar flow rates and pressures (up to 10 bar), ensuring reproducible droplet breakup and solidification kinetics.
• Compact footprint (2700 × 2600 × 3200 mm) and modular layout facilitate installation in standard Class 10,000 cleanroom or metallurgy lab environments.
• Integrated 10.1-inch industrial touchscreen HMI with preloaded operational sequences, real-time monitoring of vacuum level, coil current, melt temperature (via dual-wavelength pyrometer), gas pressure, and cooling water parameters.
• Water-cooled induction coil and crucible assembly with regulated coolant pressure (0.2–0.3 MPa) and conductivity-monitored deionized water circulation loop.

Sample Compatibility & Compliance

The GSL-1600X-VIGA300 supports a broad spectrum of conductive metallic feedstocks, including but not limited to: austenitic and ferritic stainless steels, Inconel® 625/718, Ti-6Al-4V master alloys, pure Cu, Al-Si-Mg systems, and Pt/Pd/Rh group metals. All processing occurs within a fully sealed, oxygen-controlled chamber purged to <10 ppm O₂ residual prior to atomization—meeting ASTM F3049-14 requirements for AM powder oxygen specification. The system conforms to IEC 61000-6-2 (immunity) and IEC 61000-6-4 (emission) for industrial electromagnetic compatibility. Vacuum components comply with ISO 10100:2017 (vacuum vessel design), and electrical safety follows GB/T 5226.1–2019 (equivalent to EN 60204-1). Full traceability of process parameters—including timestamps, setpoints, and alarms—is retained for GLP/GMP-aligned documentation.

Software & Data Management

The embedded control firmware records all critical process variables at 10 Hz resolution, exporting timestamped CSV files containing vacuum history, power input, gas pressure transients, and pyrometer output. Optional Ethernet/IP or Modbus TCP interfaces enable integration with centralized MES or LIMS platforms. Audit trail functionality satisfies FDA 21 CFR Part 11 requirements when paired with user authentication and electronic signature modules (available as add-on). Raw data can be post-processed using third-party tools (e.g., MATLAB, Python Pandas) for statistical grain size analysis, sphericity quantification (via SEM image segmentation), or thermal history reconstruction.

Applications

• Development and qualification of AM-ready powders for laser powder bed fusion (LPBF) and electron beam melting (EBM) processes.
• Rapid prototyping of novel alloy compositions where conventional gas atomization plants lack flexibility or minimum batch constraints.
• Production of MIM feedstocks requiring tight PSD control (Dv10/Dv90 <1.8) and surface oxide minimization.
• Fundamental research on solidification dynamics, dendrite fragmentation, and Marangoni-driven surface stabilization during inert-gas atomization.
• Reference material synthesis for inter-laboratory round-robin testing under ISO/IEC 17043 guidelines.

FAQ

What inert gases are compatible with the GSL-1600X-VIGA300?
Nitrogen (N₂) and argon (Ar) are supported; gas purity must be ≥99.99% (Grade 4.5), delivered via high-purity stainless steel lines with VCR or double-ferrule fittings.
Is the system suitable for reactive metals such as titanium or aluminum?
Yes—provided the chamber is evacuated to <1×10⁻⁴ mbar and backfilled with argon to <5 ppm O₂ prior to melting; optional oxygen sensor integration (model O₂-PROBE-EXT) is recommended for real-time monitoring.
Can particle size distribution be tuned without hardware modification?
Yes—by adjusting melt superheat, gas pressure, nozzle standoff distance, and atomization duration; empirical calibration curves are provided in the operator manual for common alloy systems.
What maintenance intervals are recommended for the diffusion pump and mechanical pump?
Diffusion pump oil replacement every 12 months or after 2000 h of cumulative operation; mechanical pump oil change every 500 h or quarterly—whichever occurs first.
Does the system include powder collection and handling accessories?
Standard configuration includes a bottom-mounted cyclone separator and HEPA-filtered glovebox-integrated powder transfer port; optional inert-atmosphere sieving station (Model SIEVE-VAC-200) is available separately.