Overview of Plasma Processing and Synthesis
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Thermal plasma processing and thermal plasma synthesis of powder and nanopowder for high-tech applications is gaining momentum, not only in research, but in industrial applications as well. High temperature gas-phase chemistry within thermal plasma environment becomes an attractive route for powder and nanopowder synthesis. The supersaturation of vapour species is the driving force for particle condensation, resulting in the production of ultrafine particles by homogeneous nucleation. Carbides, nitrides, oxides and complex solid solutions have been successfully synthesized in thermal plasma reactors based on high intensity arcs, DC plasma jets and rf inductively coupled plasmas.
The most commonly used reactants for plasma synthesis are solids. In some plasma torches the injection process suffers because of the high viscosity or momentum of the plasma. Mettech's Axial III plasma torch offers the solution for these types of obstacles.
A liquid injection method overcomes the problems associated with solid injection for powder synthesis. Still, the liquid injection method has encountered the same obstacle - penetration of droplets in the plasma plume. Mettech have developed a Suspension Plasma Spray process which can be used for thermal spray coatings, or for powder processing and synthesis. Read our Blog to learn about Mettech's approach. Due to the unique design of Axial III plasma gun, we are able to inject liquid solutions in the form of fine droplets.
Plasma Powder Processing Plant
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Mettech has designed and built a prototype 4P module to demonstrate the capability of the high capacity Axial III torch to transform almost any powder into a spheroidize and densified thermal spray grade, free flowing powder.
We have also demonstrated the ability to synthesize meta-stable and non-stoichiometric nano powders from liquid precursors and solid/lqiuid suspensions.
The 4P can also be used to surface treat powders in order to purify and glassify particle surfaces to promote full densification by hot isostatic pressure techniques and to passivate the particle surface. Download our Plasma Powder Processing Plant (4P) brochure for more information.
For more information on this topic please see our highlight on Powder Pocessing and Synthesis.