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A novel process for spheroidization of irregular shaped metallic powders

ABSTRACT Spherical morphology of metallic powder particles has great demand in powder industry. Manufacturing of such powders requires more energy which makes spherical powders expensive, whereas manufacturing irregular shaped powders is much cheaper. In present context, there has been an attempt in designing and fabricating a laboratory scale apparatus and an economical process to convert irregular powder into spherical morphology. Irregular shaped water atomised powder (size: 25–75 µm) was continuously fed into new apparatus for comminution. The processed powders were subjected to characterization using scanning electron microscopy, circularity analysis, and flow time analysis. Optimum process parameters for obtaining spherical powders have been established for the given powder. An increase in degree of spheroidization from 33.77 to 88.65% has been observed, likewise a significant increment in apparent density and decreased flow time has been recorded. It was established that cyclic wear mechanism was the predominant phenomenon in achieving improved degree of spheroidization.