Research progress on preparation technology of spherical powder
Significance Powder serves as significant industrial raw materials,with increasingly high performance requirements driven by its diverse applications.In addition to requiring very low impurity content and fine particle size with strict particle size distribu-tion,powders also need to have a certain particle morphology.Spherical powder offers distinct advantages over conventional pow-ders,mainly evident in the following aspects:1)Surface Morphology and Defects:Spherical powder exhibits uniform surface mor-phology and fewer defects,reducing the loss of mold in the production process to the finished product;2)Particle Size Distribu-tion:Spherical powders have a narrower and more uniform particle size distribution compared to irregular powders,enhancing product consistency and performance;3)Improved Mobility:The spherical shape of the powder promotes better flowability,increasing powder filling capacity,particularly beneficial in powder metallurgy applications,enhancing part density;4)Uniform Shrinkage During Sintering:Spherical powder shrinks more uniformly during sintering,facilitating grain size regulation.Given its excellent performance in surface morphology,particle size distribution and flow properties,spherical powders find extensive use across various industries.This paper presents a summary of the current status of spherical powder preparation technology based on the research progress of common spherical powder preparation technology.The different preparation principles are cat-egorized into three types:traditional physical method,chemical method,and high temperature melting method.It analyses the development of existing technology and provides a reference for future development of new technologies and theoretical research on spherical powder preparation.Progress The traditional physical method for preparing spherical powder,despite the widespread availability and low cost of raw materials,has the potential for industrialization.However,this method requires high-quality production equipment,and the indi-cators cannot be well guaranteed after the production,limiting its applicability to situations where product quality requirements are less stringent.Chemical methods for preparing spherical powders,although ensuring uniformity of particle size and high purity,tend to require significant quantities of chemical reagents(surfactants,precipitants,etc.).They face challenges in remov-ing organic impurities,are prone to agglomeration,and struggle to scale up to industrial-scale production.The high-temperature melting method is a common approach for preparing high-melting-point powders,such as quartz powder and most of the metal powder materials.This method yields powders with a high degree of sphericity,low impurity content and narrow particle size dis-tribution.The technology could be adjusted to meet different requirements according to the powder's melting point and tempera-ture range.The production process is environmentally friendly,with minimal environmental damage.The obtained spherical pow-der has significantly improved tap density,sphericity,and mobility,making the technology suitable for high-end applications.It demonstrates the preparation technology with the greatest potential for large-scale industrialized production of high-performance spherical powder materials.Conclusions and Prospects Powder spheroidization technology plays a crucial role in modern industry and technology,enhanc-ing powder properties,manufacturing precision and efficiency,and promoting green practices.It optimizes material characteris-tics to meet diverse requirements across pharmaceuticals,food,chemicals,and more.Despite advancements,challenges persist in large-scale application and theoretical research.Traditional physical methods for spherical powder production are cost-effective but struggle to guarantee particle quality,limiting suitability for high-quality products.Future developments should prioritize automation and smart manufacturing technologies,integrating advanced control systems,machine learning,and artificial intelli-gence.Establishing industry standards is essential to ensure reproducibility and comparability in spherical powder preparation processes and product properties.Spherical powders produced using chemical methods require precise chemical inputs to achieve uniform particle size and high purity.However,these methods often face challenges in removing organic impurities and preventing agglomeration,hindering industrial-scale production.High-temperature melting methods,while promising for high-melting-point powders,must address environmental concerns related to harmful emissions.Future advancements should focus on developing environmentally friendly and sustainable technologies,reducing waste generation,and utilizing eco-friendly raw mate-rials to align with global green production standards.Despite significant progress in spherical powder preparation technology,achieving highly precise regulation of particle size remains elusive,crucial for industries like biomedical and electronics.Future developments will require advanced methods for particle shape and size control,involving sophisticated process parameter con-trol,exploration of new catalysts,and catalytic reaction research.Spherical powder preparation technology transcends disciplines,including chemistry,materials science,and engineering.Promoting interdisciplinary research and collaboration is crucial for advancing the technology and addressing complex challenges.By integrating expertise from various fields,researchers can develop innovative approaches and solutions to enhance spherical powder production and application.In summary,the future of spherical powder preparation technology lies in leveraging automation,smart manufacturing,and sustainable practices to improve particle quality and meet diverse industry demands.Advancements in size and shape control,along with interdisciplinary collabo-ration,will propel innovation and widespread adoption across industries
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