Metalysis installs Tekna spheroidiser for advanced refractory alloy powder production
Metalysis, based in Rotherham, UK, reports it has acquired a 40 kW spheroidiser from Tekna Holding ASA, Sherbrooke, Quebec, Canada. The spheroidiser is designed to produce spherical powders for niche markets with high added value, and for the discovery of new alloys at development scale.
This acquisition comes as Metalysis is scaling up production of its refractory alloys – which includes tantalum and high entropy alloys – and plans to serve the high-temperature niobium market with materials such as niobium C103 and FS85. Metalysis added that this underscores its ongoing commitment to enhancing efficiency, sustainability and innovation in Powder Metallurgy.
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Using the patented FFC Cambridge electrolysis process, Metalysis reduces metal oxides in the solid state, a method that contrasts with traditional melting processes. Typically, this process outputs powders with an angular shape, but the spheroidiser can be used to produce spherical particles for Powder Metallurgy applications.
Use of the spheroidiser enhances Metalysis’ in-house capabilities, improving attributes such as powder flowability, reducing internal porosity, and delivering higher packing density. This can meet the most demanding Powder Metallurgy applications, including Additive Manufacturing, Metal Injection Moulding, Spark Plasma Sintering, and Hot Isostatic Pressing.
A key feature of the Metalysis FFC Cambridge technology is the ability to tailor particle size for a given process while generating minimal under- or oversize particles. This characteristic is maintained post-spheroidisation, resulting in negligible waste powder being created compared to conventional atomisation processes, and consequently, energy is not consumed in the generation of scrap powder.
Nitesh Shah, CEO of Metalysis, shared, “The acquisition of a 40 kW spheroidiser marks a major step forward in Metalysis’ capability to produce advanced powders in-house and serve our niche but high-value markets – particularly in refractory alloys and lightweight refractory high entropy alloys. By controlling our spheroidisation processes, we’re not only reducing lead times and mitigating global supply chain risks, but also reinforcing our sustainable footprint. This is a pivotal moment for Metalysis as we strengthen our position in the critical materials supply chain – now able to provide spheroidised powders in-house.”
