Arcast forms new company to focus on bulk production of challenging alloy powders

August 24, 2016

Arcast forms new company to focus on bulk production of challenging alloy powders

Arcast’s atomiser products range from 5-200kg conventional batch type ceramic/refractory based close coupled gas atomisers to free fall atomisers for reactive metals such as titanium

Arcast Inc., based in Oxford, Maine, USA, a specialist in arc and induction melting systems, has announced it is creating a new company, Arcast Materials, to focus on the bulk production of a number of challenging alloys including titanium alloy powders.

The company forecasts that production of clean titanium alloy powders will be in the order of ‘tonnes per month’ once the new plant is operating at its full potential. This will directly feed the growing Powder Metallurgy market, especially in the areas of Additive Manufacturing and associated net shape production techniques.

In recent years, Arcast has concentrated on developing gas atomisation systems for the production of metal powders. In 2015 Arcast was awarded a contract by the Swedish steel company Uddeholms AB to build a 200 kg capacity gas atomiser. This system, for the production of tool steel powders, was signed off in August 2016.

Also in 2015, Arcast won an order from a single North American customer to manufacture two gas atomisers, one for the production of nickel alloy powders (120 kg capacity) and the other to produce aluminium powders (40 kg capacity). These systems have been installed and are in the process of being commissioned.

In 2011, Arcast recieved a SBIR Phase I grant of US$150,000 from the National Science Foundation for the development of a new method for reactive and refractory metal processing. Arcast was subsequently awarded a Phase II grant of US$500,000.

The NSF funding has allowed Arcast to develop a method for taking elemental refractory or reactive metal and melt, alloy and atomise or cast it in one continuous process. The process is completely ceramic free allowing clean, contamination-free alloys to be produced. The theoretical properties of these advanced materials in pure form can be maintained without the risk of ceramic inclusions.

The continuous nature of the Arcast process, from raw material to finished product (powder), is claimed to consume a fraction of the energy used by the collection of processes and methods currently used by industry to achieve the same results. It also greatly reduces the costs involved, allowing a greater range of metal powders to be produced more cost effectively. The single process reduces lead times and contamination.

Now that the process has been proven and set up for production, Arcast states that it is working with customers in various sectors to produce these advanced materials. Such materials will include shape memory alloys, thermo-electric materials and alloys used in aerospace and medical markets and in additive and other net shape manufacturing methods.

Latest Industry News

Download the latest issue of PM Review

Our latest issue is now available to download in PDF format, free of charge.

As well as an extensive Powder Metallurgy industry news section, this 120-page issue includes the following exclusive articles and reports:

  • Tesla teardown: Identifying potential uses for PM in electric vehicle transmissions
  • Can European research still claim to be ‘world class’? Prof José M Torralba on the changed PM research base
  • How to make metal powders. Part 1: An introduction to atomisation, process fundamentals and powder characteristics
  • Starting out in powder production: The story of Fomas Group’s Mimete metal powder business
  • The creation of a Powder Metallurgy market leader: China’s NBTM New Materials Group Co., Ltd.
  • Tungsten heavy alloys: An exploration of how key property combinations enable better mechanical performance
  • Pharmaceuticals and PM are closer than you think: A new approach to understanding powder compaction and tablet characterisation
  • More information

Industry News


Sign up to our free e-newsletter, sent weekly to industry professionals around the world. We'll also let you know each time a new issue of PM Review magazine is available.

Subscribe for a FREE digital magazine

PM Review is the leading international magazine for the Powder Metallurgy industry.
Published four times a year, it is available as a free download or through a print subscription

Connect with us

Powder Metallurgy: The original net-shape production process

Powder Metallurgy components are relied upon by a wide variety of manufacturing industries, from automotive to power tools, household appliances, chemical engineering, filtration and more.

The main reason for the technology’s success is its cost-effectiveness at producing high volumes of net-shape components, combined with its ability to allow the manufacture of products that, because of the production processes, simply cannot be manufactured by other methods.

To discover more about how the technology has revolutionised component production, browse our Introduction to Powder Metallurgy.

Latest industry news

Copy link