Method for preparing powder material and application thereof

Abstract

The present disclosure provides a method for preparing a powder material and an application thereof. The preparation method includes: obtaining an initial alloy ribbon including a matrix phase and a dispersed particle phase by solidifying an alloy melt, and then removing the matrix phase in the initial alloy ribbon while retaining the dispersed particle phase, so as to obtain a powder material composed of original dispersed particle phase. The preparation method of the present disclosure is simple in process and can prepare multiple powder materials of nano-level, sub-micron-level and micro-level. The powder materials have good application prospects in the fields such as catalytic materials, powder metallurgy, composite materials, wave-absorbing materials, sterilization materials, metal injection molding, 3D printing and coating.

1 . A method for preparing a powder material, comprising the following steps:
 at step 1: selecting initial alloy raw materials, and melting the initial alloy raw materials according to a ratio of initial alloy ingredients to obtain a homogeneous initial alloy melt containing an impurity element T, wherein T comprises at least one of O, H, N, P, S, F, Cl, I, and Br, and an average ingredient of the initial alloy melt is A a M b T d ; wherein when M comprises B, A comprises Zn; when M comprises at least one of Si and Ge, A comprises Zn; a, b and d represents atomic percent contents of corresponding constituent elements, and 60%≤a<99.5%, 0.5%≤b<40% and 0<d≤10%;   at step 2: solidifying the initial alloy melt into an initial alloy ribbon; wherein a solidification structure of the initial alloy ribbon comprises a matrix phase and a dispersed particle phase; the matrix phase has a lower melting point than the dispersed particle phase, the dispersed particle phase is wrapped in the matrix phase; during the solidification of the initial alloy melt, the impurity element T in the initial alloy melt is redistributed in the dispersed particle phase and the matrix phase, and is enriched in the matrix phase, so as to purify the dispersed particle phase;   wherein a major ingredient of the dispersed particle phase in the initial alloy ribbon is M x1 T z1 , an average ingredient of the matrix phase is mainly A x2 T z2  and 98.5%≤x1≤100%, 0≤z1≤1.5%; 80%≤x2<100%, 0<z2≤20%; z1<d<z2; x1, z1, x2, and z2 represent atomic percent contents of the corresponding constituent elements respectively;   at step 3: removing the matrix phase in the initial alloy ribbon, and retaining the dispersed particle phase which is not removed at the same time during the removal of the matrix phase; collecting the separated dispersed particle phase, so as to obtain a target high-purity powder material composed of original dispersed particles.   
     
     
         2 . The method of  claim 1 , wherein a method for removing the matrix phase in the alloy ribbon comprises at least one of acid reaction removal, alkali reaction removal, vacuum volatilization removal, and matrix phase natural oxidation-powdering peeling removal. 
     
     
         3 . The method of  claim 1 , wherein the target powder material has a particle size of 2 nm to 3 mm. 
     
     
         4 . An alloy ribbon, comprising an endogenous powder and a wrapping body; a solidification structure of the alloy ribbon comprises a matrix phase and a dispersed particle phase, the matrix phase is the wrapping body, and the dispersed particle phase is the endogenous powder; the wrapping body has a lower melting point than the endogenous powder, and the endogenous powder is wrapped in the wrapping body;
 a major ingredient of the endogenous powder in the alloy ribbon is M x1 T z1 , an average ingredient of the wrapping body is mainly A x2 T z2 ; and 98.5%≤x1≤100%, 0≤z1<1.5%; 80%≤x2<100%, 0<z2≤20%; z1<z2; x1, z1, x2, and z2 represent atomic percent contents of the corresponding constituent elements respectively; wherein when M comprises B, A comprises Zn; when M comprises at least one of Si and Ge, A comprises Zn; and T comprises at least one of O, H, N, P, S, F, Cl, I, and Br.   
     
     
         5 . A method for preparing a powder material, comprising the following steps:
 selecting an initial alloy with an ingredient A a M b , wherein a and b represents atomic percent contents of corresponding constituent elements, and 0.1%≤b≤40%, a+b=100%;   when M is at least one of Si and Ge, A comprises Zn;   when M is at least one of B, Cr, and V, A is Zn;   when M is C, A comprises Zn;   fully melting the initial alloy to obtain an initial alloy melt, wherein during subsequent cooling and solidification processes, no intermetallic compound is formed between A and M, but separation of A and M occurs, so that a solidified state alloy in which a dispersed particle phase with an ingredient M is distributed in a matrix phase A is obtained; removing the matrix phase A in the solidified state alloy, so that the dispersed particle phase which is not removed at the same time is retained and separated out in a dispersed manner so as to obtain a powder material with the ingredient M.   
     
     
         6 . The method of  claim 5 , wherein the matrix phase A is removed by one of acid reaction removal, alkali reaction removal, and vacuum volatilization removal. 
     
     
         7 . An application of the powder material prepared by the method of  claim 1  in catalytic materials. 
     
     
         8 . An application of the powder material prepared by the method of  claim 1  in powder metallurgy. 
     
     
         9 . An application of the powder material prepared by the method of  claim 1  in composite materials. 
     
     
         10 . An application of the powder material prepared by the method of  claim 1  in coatings. 
     
     
         11 . The alloy ribbon of  claim 4 , wherein the alloy ribbon has a thickness of 5 μm to 10 mm, and a width of a cross section of the alloy ribbon is two or more times the thickness. 
     
     
         12 . The alloy ribbon of  claim 4 , wherein the endogenous powder has a particle size of 2 nm to 99 μm. 
     
     
         13 . The alloy ribbon of  claim 4 , wherein the endogenous powder has a particle size of 2 nm to 1 μm.