LIBERTY Powder Metals opens new high-tech metals facility

LIBERTY Powder Metals, has completed first production at its high-tech new Teesside, North East England, powder metals facility, targeting fast-growing demand in advanced manufacturing and 3D printing.

LIBERTY Powder Metals will produce a range of stainless steel and nickel superalloy powders for precision components in demanding sectors such as automotive, aerospace and engineering, the premium end of the global powder metals market already worth more than £2bn a year.
The cutting-edge powder production process cuts carbon emissions by 85% compared to the traditional steel route, part of LIBERTY Steel’s CN30 strategy that will make the company carbon neutral by 2030.

The landmark is the culmination of a two-year collaboration with the Tees Valley Combined Authority, which provided £4.6mn of funding, and the Materials Processing Institute, which housed the atomiser beside its own research facilities. Atomising Systems Ltd and Consarc Engineering have worked closely on equipment design.

Installation and commissioning have successfully overcome significant challenges caused by the coronavirus pandemic, which has restricted the number of contractors able to work on site and impacted on the delivery of equipment.

The technical details
Minute spherical powder particles are processed to the highest specifications in a vacuum induction argon gas atomiser, the only one of this kind in the UK, with a unique anti-satellite facility to increase productivity.
Commissioning of the powder metals facility, known as an atomiser, includes a series of ‘acceptance melts’ which LIBERTY must perform before the plant is handed over for full operation. The facility allows LIBERTY to melt a range of defined chemistries and pour the liquid stream through an aperture, using inert gas to break this into fine droplets, which then solidify to create powder, secure and confined in the atomiser to avoid contamination from outside sources.
The powders undergo further processing including optimisation and characterisation before final tests and despatch to customers. The same post-atomisation processing activities are deployed for all metal powders in an extensive portfolio which includes aluminium, titanium and cobalt alloys.

Top picture:  L to R. Dan Frith, Manufacturing and Engineering Manager, Tees Valley Mayor, Ben Houchen, LIBERTY Powder Metals General Manager, Dr Simon Pike.