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UFP's proprietary powder production processes have moved from the lab to pilot plant, and in 1990 went into full scale production. UFP's melt furnaces utilize unique design features for powder atomization with an unusually high yield of smaller particles. Gas atomization also produces consistent, spherical particles in contrast to the irregular particles produced by water atomization. Sphericity is critical for the requirements of many specialty applications.
The furnaces, each with remote monitoring and control, are closed systems in which metal is melted under inert gas to provide protection against oxidation. The liquefied metal is then atomized by a high velocity gas stream. The resulting particles are shaped as they cool and fall through the atmosphere-controlled chamber. UFP's process is not subject to oxygen or nitrogen contamination which reduces the purity of many conventionally-produced powders.
Powder coming from the chamber then enters a classifier which utilizes centrifugal force and counterflow gas for greater precision in particle size separation as compared to simple mechanical screening.
UFP is able to achieve even greater economy in its production by capturing and recycling its atomization gases for reuse. Additional economies are achieved through rigorous quality control of incoming materials, and the fact that UFP's high quality, spherical powders do not require secondary operations such as annealing which is typical of ferrous powder production. UFP customers benefit from continuity of supply, product consistency, and favorable cost. |
