Atomization results in a fine powder whose average particle size can be regulated over a wide range. Resultant powders are of high purity. Excessive oxidation, characteristic of other atomized products, does not occur because of the rapid chilling effect of the expanding gases released through the nozzle Thus, the oxygen content of atomized tin is normally below 0.2%. The thin film of oxide produced during atomization with steam or air is sufficient to inhibit further oxidation of the particles.

The molten tin can be atomized vertically (up or down) or horizontally, depending on the nozzle direction, to produce a powder (Fig. 1). There are two atomization techniques: annular nozzle and cross-jet atomization. In an annular nozzle, the gas stream aspirates liquid tin into the nozzle, where it is disintegrated into tiny droplets by the high-velocity gas stream. In cross-jet atomization, the gas is at right angles to the molten tin stream. This method usually produces coarser particles than annular nozzles.

Fig. 1 Schematic of apparatus for atomizing tin powder

To atomize uniformly fine tin powders, temperature, stream diameter, and flow rate of the molten tin and temperature, pressure, velocity, and angle of impingement of the atomizing gas must be well controlled. Pressures commonly employed to atomize tin powder range from 345 to 1725 kPa (50 to 250 psi). Generally, finer powders require the higher pressure; however, the exact pressure is related to the nozzle design used.

Compressed air is usually used as an atomizing medium. It is frequently preheated in a gas-fired heat exchanger to prevent solidification of tin within or around the orifice caused by the chilling effect of expanding air as it is released through the nozzle. Nozzles are designed to facilitate the atomization of several different particle size ranges, usually by changing orifice diameter and air pressure.

A blower (fan) at the end of the system pulls the atomized tin powder from the atomization chamber into a cyclone, where it is collected. The finest particles, which have not settled in the cyclone, are then retained in the cyclone filters. The tin powder collected in the cyclone is sieved to remove the oversized particles, most commonly +100, +200, or +325 mesh.

A uniform mixture of tin powder of the desired lot size is produced by tumbling in a blender. A sample of the blended tin is then analyzed for physical and chemical properties. The tin powder is packed in steel or waterproof fiber containers weighing up to 320 kg (700 lb).

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