ASTM-grade metal powder is a cornerstone of advanced manufacturing, providing the precise material properties needed for additive manufacturing (AM), aerospace applications, and other high-performance uses. These powders must meet stringent specifications to ensure consistent quality and reliability in demanding applications. Traditionally, these powders are produced from virgin metal, a resource-intensive process involving mining, refining, and various methods of atomization.
The word "scrap" often carries a negative connotation—suggesting something dirty, useless, or discarded. But at Continuum Powders, we see untapped value in scrap metal. By transforming previously used and discarded metal into something valuable again, we can unlock a wealth of potential. Truth be told, there is another path forward: reclaiming metal “scrap” and turning it into something useful and even more valuable. By transforming existing metal parts into high-quality powders, we can create a sustainable, cost-effective solution that meets the high standards of ASTM-grade materials. Reclaiming metal scrap not only addresses supply chain challenges but also contributes to environmental stewardship and a circular economy.
The Challenges of Traditional Metal Powder Supply Chains
Traditional metal powder supply chains are heavily reliant on virgin metal extraction and processing. This reliance comes with significant environmental and economic costs. It’s no secret that mining for raw materials is energy-intensive and contributes to carbon emissions, habitat destruction, and other forms of environmental degradation. Furthermore, the cost of virgin metal fluctuates, subject to market volatility, which can impact the financial stability of manufacturing operations.
In this context, adopting a circular economy model offers a promising alternative. A circular economy emphasizes minimizing waste and keeping resources in use for as long as possible. By reclaiming and repurposing metal waste, manufacturers can reduce their reliance on newly extracted materials, decrease environmental impact, and create a more resilient supply chain.
The Process of Reclaiming Metal Scrap
Reclaiming metal scrap into ASTM-grade powder involves several critical steps, each designed to ensure the final product meets stringent quality standards:
1. Collection and Sorting: The process begins with collecting metal scrap, which is then sorted based on material type and alloy composition. Proper sorting is crucial to maintain the quality and performance of the final powder.
2. Cleaning and Processing: The sorted metal scrap undergoes cleaning to remove any impurities, such as oil, dirt, or other contaminants. This step ensures that the final powder is free of impurities that could compromise its properties.
3. Size Reduction: The cleaned metal is then subjected to size reduction, typically through shredding or milling. This step prepares the material for atomization by breaking it down into smaller, more manageable pieces.
4. Atomization: During atomization, the metal is melted and then converted into powder by spraying it through a nozzle using gas or water. This process produces fine, uniform particles that are essential for advanced manufacturing applications.
5. Quality Control and Testing: Finally, the reclaimed powder undergoes rigorous quality control and testing to ensure it meets ASTM-grade specifications. Advanced technology and expertise are essential in this phase to guarantee that the reclaimed powder performs at the same level as, or even better than, virgin material.
Continuum Powders' Approach to Powder Lifecycle Management
At Continuum Powders, we offer a powder management solution designed to maximize both efficiency and sustainability. Our innovative technologies and sustainable practices ensure that reclaimed powders meet or exceed industry standards.
Our proprietary Greyhound M2P platform revolutionizes the metal additive manufacturing industry by transforming reclaimed metal into high-quality Continuum OptiPowders. This innovative process ensures that the resulting powders meet the exacting standards required for advanced manufacturing applications, such as Laser Powder Bed Fusion (LPBF), Electron Beam Melting (EBM), Binder Jetting, etc.
Starting with metal sourced from industries like aerospace, automotive, and electronics, we implement rigorous quality control measures throughout the entire process. The waste undergoes meticulous preparation and sorting to ensure consistency in quality and composition.
Next, the prepared metal waste is melted in a high-temperature furnace and then atomized, creating tiny, spherical powder particles. This atomization process is essential for producing powders with the ideal characteristics for additive manufacturing.
The resulting metal powder is subjected to stringent testing to evaluate its particle size distribution, flowability, and chemical composition. By adhering to the highest standards, we guarantee that our Continuum OptiPowders are suitable for demanding AM applications.
Continuum Powder’s Greyhound M2P technology is a testament to our commitment to sustainability and circular economy practices. By transforming previously used or discarded metal into valuable resources, we contribute to a more environmentally friendly and efficient metal additive manufacturing industry.
Here’s our process at a glance:
- Greyhound Melt-to-Powder (M2P) Technology: Our proprietary technology converts used metal alloys into high-quality powders in a single step, maintaining optimal particle size and shape for AM applications.
- Certified Reclaimed Powders: We ensure all reclaimed powders are ASTM-grade, matching or surpassing the quality of virgin materials for demanding applications like LPBF.
- Lifecycle Management Services: Continuum Powders assists with powder collection, re-atomization, and reprocessing to extend the lifecycle of your materials.
- Technical Support: Our team provides expertise to help customers optimize powder performance throughout production.
Through this comprehensive approach, Continuum Powders ensures that every stage of the powder lifecycle supports operational efficiency while contributing to environmental goals.
Benefits of Using Reclaimed Metal Powder
Reclaiming metal scrap significantly reduces the environmental impact associated with traditional metal powder production. By minimizing waste and reducing the need for new mining activities, reclaimed metal powders contribute to a more sustainable manufacturing ecosystem. This approach also supports a circular economy, where materials are kept in use and their lifecycle extended, reducing the overall demand for raw resources.
It's worth acknowledging that reclaimed metal powders can be produced at a lower cost compared to virgin materials. The reduction in raw material extraction and processing translates to cost savings, which can be passed on to manufacturers. Additionally, the use of reclaimed powders offers potential long-term savings by creating a more stable and predictable supply chain.
Of course, contrary to misconceptions, reclaimed metal powders can meet or exceed ASTM-grade standards. At Continuum Powders, our advanced processing techniques ensure that reclaimed powders offer the same strength, ductility, and impact resistance as virgin metals. Our proprietary methods provide manufacturers with high-quality materials that do not compromise on performance.
The consistency and reliability of reclaimed metal powders make them a viable supply source for advanced manufacturing. By leveraging state-of-the-art processing technologies and stringent quality control measures, Continuum Powders ensures that each batch of reclaimed powder delivers consistent results, helping manufacturers maintain high standards of quality.
Out With the Old…
A great example of effective powder lifecycle management is our Knust-Godwin case study. Faced with managing the end-of-life Ni718 components for a major oil and gas company, Knust-Godwin turned to Continuum Powders for a sustainable solution. Through our M2P technology, the used components were reclaimed and converted into premium OptiPowder Ni718, ready for reuse and resulting in significant cost savings, reduced material waste, and parts that met the same high standards as those made from virgin powders.
Read the full case study here
In With the New
Reclaimed metal powder offers a sustainable, cost-effective, and high-quality alternative for advanced manufacturing. By reducing environmental impact, supporting a circular economy, and providing reliable, ASTM-grade materials, reclaimed powders present a compelling solution for the future of the metal powder industry.
As we look ahead, it’s time to rethink how we source our materials and embrace the opportunities offered by material reclamation. Incorporating reclaimed metal into supply chains makes sense from an environmental perspective and delivers real economic and performance benefits.
At Continuum Powders, we want to work with you to build a more sustainable, resilient future for advanced manufacturing. Contact us for a quote or explore our high-quality, sustainable OptiPowders.
