First, let's explain laser powder bed melting (LPBF), also known as selective laser melting (SLM). The process uses a high-energy laser beam as a heat source to selectively and completely melt a flattened layer of metal powder, based on a three-dimensional digital slice model of the part. The molten pool rapidly cools and solidifies, forming a strong metallurgical bond with the previous or surrounding material. This process is repeated layer by layer to ultimately form a three-dimensional solid part. Its main advantage is that the density and mechanical properties of the formed parts are usually close to or even exceed those of traditional forgings. In the application of titanium alloys, due to the high cost of materials, they are mainly used in a few high-value-added fields such as medical implants, aerospace components, and high-end automotive and racing parts. Ti64, or Ti-6Al-4V, is an (α+β) dual-phase titanium alloy. Through the combination of aluminum (α-phase stabilizing element) and vanadium (β-phase stabilizing element), it achieves excellent comprehensive properties, thus becoming the most widely used titanium alloy. It contains approximately 6% aluminum (Al) and approximately 4% vanadium (V), with the remaining approximately 90% being titanium (Ti), hence its name. Previously, we primarily produced fine Ti64 powder (typically 15 to 45 microns) for LPBF systems. Besides the aforementioned high cost, the small particle size of this powder increased flammability and inhalation risks, and it was also classified as a hazardous material. Companies had to invest in control, ventilation, and storage infrastructure, all of which limited the application of Ti64 material in 3D printing. The company investigated whether coarser titanium powder could achieve faster printing while maintaining material integrity, validating its feasibility from both production and application perspectives. Specifically, coarser powder reduces atomization and sieving costs, increases yield, and generates less waste. Because it is not classified as a hazardous material, logistics and storage are simplified, reducing compliance and transportation costs. Reduced dust formation also reduces health risks for operators, contributing to a safer and more sustainable manufacturing environment. According to Tekna, this powder allows for thicker build-up layers-approximately 90 microns, compared to the traditional 30 or 60 microns-thus increasing printing speed without sacrificing part strength or surface quality. On the production side, its radio frequency (RF) inductive plasma atomization process was applied, in which titanium wire is fed into a plasma torch, melted, and transformed into droplets that cool into spherical powder particles. This continuous, contamination-free process minimizes pollution because no electrodes or gas nozzles come into contact with the molten metal. The resulting powder exhibits high sphericity, uniform chemical composition, and good flowability-properties crucial for repeatable additive manufacturing production. On the application side, the powder was validated through laser parameter optimization, density measurement, and flow testing to confirm its performance on commercial LPBF systems.
Our innovative technological solutions: DFIA
1: High-efficiency atomization system: A supersonic high-efficiency atomization system achieves a powder recovery rate of over 70% (relative to raw materials) for 0-53µm powder.
2: Flexible intelligent continuous feeding system: Combining infrared vision technology, a flexible control system, and precision spiral docking technology, it achieves intelligent continuous production, increasing production efficiency by 10 times (30KG/h) and solving batch consistency issues.
3: Adaptive variable circulation argon recovery system: High flow rate (1600Nm3/h), high pressure (60-80Bar), multi-stage pressurization adaptive online recovery reduces argon consumption by over 95%, achieving cost reduction and efficiency improvement.
4: High-efficiency "shallow" aggregation induction melting technology: Achieves optimal electromagnetic induction effects, increasing the superheat of the molten metal by 250-300°C.
Our product's advantages:
Oxygen content below 1500ppm;
0-15µm powder yield ≥25%;
Powder sphericity ≥90%;
Production efficiency ≥30KG/H.
For technical questions regarding GR5 titanium alloy spherical powder, please contact us.
