Eliminating Contamination: How Zircoa Solved Critical Aerospace Powder Qualification Challenges
When a leading specialty alloy manufacturer faced contamination issues threatening critical aerospace qualifications, they needed more than just a supplier. They needed a problem-solving partner who could respond with urgency and precision.
The Challenge: Contamination Threatening Aerospace Qualification
A specialty alloy manufacturer operates a powder production facility specializing in metal powders for hot isostatic pressing, additive manufacturing, and coating applications. These materials require absolute cleanliness and consistency.
The facility operates an ALD Vacuum Induction Melting Inert Gas Atomizer (VIGA) to produce these critical metal powders. In gas atomization, molten metal streams through zirconia atomization nozzles, where high-pressure inert gas breaks it into fine powder particles. The bore diameter and surface quality of these atomization nozzles directly impact powder particle size distribution and cleanliness. When supplying aerospace engine components, these factors are non-negotiable.
The manufacturer faced a significant problem with their existing nozzle supplier. The OEM manufacturer supplied zirconia atomization nozzles with machined bores to achieve tight tolerances. While this machining delivered dimensional precision, it created an unintended consequence: the machining process left microscopic zirconia particles that contaminated the metal powder during atomization.
For aerospace-grade metal powders destined for critical rotating components in aircraft engines, contamination from refractory was unacceptable. The manufacturer was pursuing qualification to supply metal powders to a global aerospace engine manufacturer, and the contamination from machined nozzle bores was causing them to fail qualification requirements. The situation was urgent. Without resolving this issue, the manufacturer faced:
- Failure to meet qualification requirements for key aerospace accounts
- Loss of competitive position against other powder metal producers
- Continued contamination of aerospace-grade powders
- Violation of customer requirements (machined bores were technically not allowed)
The manufacturer needed a supplier who could provide contamination-free atomization nozzles with the necessary tolerances, performance characteristics, and most importantly, speed.
The Solution: As-Pressed Bores and Rapid Response
Zircoa was already supplying atomization nozzles to another facility within the manufacturer’s operations, establishing a foundation of technical knowledge and trust. When the powder operations team reached out with their urgent contamination challenge, Zircoa moved quickly to evaluate the requirements and develop a solution.
The technical review process identified the core issue: eliminating the need for bore machining while maintaining the tight tolerances required for consistent powder production. Zircoa proposed supplying atomization nozzles in magnesia partially stabilized zirconia with as-pressed bores, meaning the critical bore dimension would be formed during the pressing process rather than machined afterward.
This approach offered several critical advantages:
- Eliminated contamination source entirely – No bore machining meant no zirconia particles to shed into the powder stream
- Achieved necessary bore tolerances – Precision pressing and tooling design delivered the tight tolerances required for consistent powder production
- Provided balanced thermal and mechanical properties – The zirconia composition offered the strength and wear resistance needed for demanding atomizer conditions
- Enabled rapid trial production – Domestic manufacturing capabilities allowed Zircoa to meet urgent qualification deadlines
Zircoa structured a trial schedule to meet the manufacturer’s qualification deadlines, supplying trial nozzles with urgency. The manufacturer evaluated the trial results across multiple criteria:
- Elimination of contamination from the press-and-sinter bore
- Consistency and repeatability of bore size tolerances
- Quality of the powder produced (size, shape, and surface finish)
- Mechanical and thermal performance of the zirconia material in the atomization system
The trials confirmed that Zircoa’s as-pressed nozzles delivered contamination-free operation while maintaining the powder quality characteristics needed. The material proved compatible with the ALD system, and the bore tolerances remained consistent across production runs.
The Results: Qualification Achieved and Partnership Established
With Zircoa’s contamination-free zirconia atomization nozzles, the manufacturer successfully met the qualification requirements for their key aerospace accounts, enabling them to supply metal powders for critical aircraft engine components. The as-pressed bore solution eliminated the contamination risk that had threatened this qualification, giving them confidence in their powder cleanliness.
Beyond solving the immediate contamination problem, Zircoa’s solution delivered operational improvements. Domestic supply of consumable nozzles improved lead times compared to international OEM sources. Zircoa’s commitment to maintaining safety stock and responsive customer support gave the manufacturer greater supply chain confidence. The rapid trial response demonstrated Zircoa’s capability to quickly react and provide customized solutions in highly technical atomization applications.
The project established an ongoing supply relationship, with Zircoa continuing to provide atomization nozzles that meet the manufacturer’s quality, lead-time, and responsiveness requirements. For the customer, the partnership meant more than just solving a contamination problem; it meant gaining a supplier who understood the urgency of aerospace qualifications and could deliver engineered solutions under pressure.
Facing contamination challenges in your powder metallurgy operations? Zircoa’s engineering team can evaluate your atomization requirements and develop customized zirconia solutions. Contact us to discuss your application.