Gas Atomisation of Metals and Hot Isostatic Pressing (HIP)

With our gas atomisation system we are able to offer:

• Melting and atomisation in an inert atmosphere
• Low oxygen content metal powders
• Spherical particles
• Screened particle size ranges
• Production of small batch sizes
• Reactive alloy powders
• Liquidus temperatures of up to 1500°C

The capacity of our gas atomiser allows the production of small volumes of metal powders without fear of cross contamination from previous batches.  Our ability to make small batches make us a cost-effective alternative for development of bespoke powders.

We also offer High Energy Mechanical Alloying as an alternative to gas atomisation, which can be used when materials are difficult or impossible to produce by casting or atomisation. Mechanical alloying is a precise reproducible method that gives good compositional control and microstructural homogeneity.

Hot Isostatic Pressing (HIP)

Hot Isostatic Pressing (HIP) involves the simultaneous application of elevated temperature and pressure and is a powerful fabrication process of advanced engineering materials. Ceram's HIP facility has a maximum capability of 2000°C and 200 MPa, with a working chamber of up to 200 mm in diameter and 300 mm in height.

Typical applications include:

• Elimination of residual porosity in metallic or ceramic parts.
• Consolidation to full density of metallic, ceramic or metal matrix composite powders.
• Diffusion bonding of dissimilar materials to form coherent hybrid components.

The process can yield property enhancements in monolithic materials and improved performance in hybrid tooling where differing materials are strategically disposed to suit the varying service requirements of tooling. 

• Dedicated cycles designed to meet your exact requirements.  
• Development of HIP cycles that maximise the required material properties.
• Comprehensive technical back-up providing advice on material combinations, design and optimum processing parameters.

In-house Electron Beam Welding (EBW) facilities enable the hermetic encapsulation of powders to be consolidated or materials to be diffusion bonded.  This facility is also suited to the direct joining of composite cores for enhanced heat extraction and reduced cycle time in plastic injection moulding.

Ceram is involved in a diverse range of HIP projects, ranging from fundamental research to pilot-scale manufacture.  Examples of areas in which Ceram has been involved:

• DU-Zircaloy and Ta-W Neutron Spallation Target Modules
• Certified Reference Materials
• Hybrid Tooling for:
  • Mining
  • Extrusion
  • Forging
  • Plastic Injection Moulding
  • Pressure Die-casting.