Metal Powders For Filtration

Jiangsu Crystal Additive Manufacturing Co., Ltd. produces filtration-grade metal powders — irregularly shaped metal sand used as filter media in synthetic fiber spinning packs and polymer melt filtration. From our plant in the Jiangyan District of Jiangsu Province we supply nickel-based, cobalt-based, iron-based, copper-based and composite tungsten carbide powders, together with custom pure nickel, pure cobalt and pure copper powders, for filtration, thermal spray, laser cladding and powder metallurgy processes.

Metal Sand as Filter Media in Synthetic Fiber Spinning

Filter media sits behind the spinneret inside the spinning pack, removing gels, agglomerates, undispersed particles and inorganic contaminants before the polymer reaches the capillary. Alumina sand and woven metal mesh carried that duty for decades. As Metal Powders For Filtration Manufacturers, we produce the irregular-shaped metal sand that has progressively replaced both.

The change follows spinning economics rather than fashion. Irregular particles interlock into a stable bed with a controlled void structure, so a given pack volume can hold a finer filtration rating without an unacceptable rise in pressure. More consistent filament quality and fewer breaks follow from that stability.

Comparing Filtration Media for Spinning Packs

Alloy Systems We Produce for Filtration Service

Specification Variables That Decide Filtration Behaviour

• Particle size distribution and cut point — the classified cut sets the nominal filtration fineness and the pressure the bed develops.
• Morphology — angular, irregular particles interlock and build depth filtration; spherical particles flow more freely and pack differently.
• Apparent and tap density — determines how much powder a fixed pack volume holds and how the bed settles under flow.
• Oxygen content — low oxygen supports clean melting behaviour and reduces oxide inclusions reaching the polymer stream.
• Chemistry and corrosion resistance — nickel and cobalt systems resist attack in hot polymer; iron systems cover less aggressive duty.
• Surface condition and fines level — controlled surface oxide and a low fine fraction keep extractables and pressure spikes under control.
• Flowability — matters for automated filling and for reproducible pack-to-pack weight.

How the Powder Is Made and Why Morphology Matters

We run three powder production routes — vacuum atomization, gas (aerosol) atomization and water atomization — followed by screening, classification and drying. Each route leaves a different particle signature, and the route is chosen from the process the powder has to serve.

• Water atomization — high-pressure water breaks the melt into droplets that solidify quickly, giving the irregular, angular particles used as filtration sand.
• Gas atomization — inert gas atomization produces spherical and sub-spherical particles with good flowability for thermal spray, laser cladding and additive manufacturing.
• Vacuum atomization — melting and atomization under vacuum or gas protection keeps oxygen and nitrogen pickup low.
• Classification — cyclone separation and screening set the particle size distribution and strip out the fine fraction that would blind a pack.

Quality Control and Batch Documentation

Production is managed under an ISO 9001-based quality system, with chemical composition and particle size range controlled to the customer's specification for every batch. Test values are recorded against the production batch so the delivered lot can be traced to its analysis.

• Chemical composition by ICP and wet analysis
• Oxygen, nitrogen and hydrogen by inert gas fusion
• Carbon and sulphur analysis
• Particle size distribution by laser diffraction and sieve analysis
• Apparent density, tap density and flow rate
• Hardness testing on consolidated samples
• Industrial CT for internal defect checks

Loading, Sealing and Change-Out Practice

• Fill weight — the pack is charged by weight rather than volume; we confirm the weight that matches the target bed depth.
• Settling — tapping or vibration during filling gives a reproducible bed and avoids later compaction under flow.
• Support and retention — a support screen or sintered plate below the bed and a retention layer above keep the media in position.
• Sealing — the pack seal, not the powder, usually sets bypass risk, so the media cut has to match the housing geometry.
• Differential pressure — start-up pressure and the rate of rise define the change-out point.
• Cleaning — metal sand beds can be cleaned by thermal removal of polymer residue where the housing allows it.

Information We Use to Configure Your Solution

Customization, Packaging and Delivery Scope

Beyond the standard filtration grades we produce custom pure nickel, pure cobalt and pure copper powders, blended chemistries and customer-specific particle size cuts. Related alloy systems for coating and cladding duty include Nickel Based Metal Powder, Cobalt Based Alloy Powder and Copper Based Alloy Powder.

• Packaging format and unit weight agreed at order
• Batch labelling with grade, cut, weight and analysis reference
• Palletised or loose-loaded delivery to the customer's forwarder
• Documentation package matched to the customer's incoming inspection routine

Frequently Asked Questions

What particle size do you supply for filtration metal sand?

We produce to the cut the pack design calls for, from coarse support grades to fine filtration cuts, with the distribution set by screening and classification. The right cut balances filtration fineness against the pressure drop the spinning line can tolerate, so we confirm it against the pack geometry and melt conditions.

Can you supply pure metal powders instead of alloys?

Yes. Pure nickel, pure cobalt and pure copper powders are produced to customer chemistry, alongside nickel-based, cobalt-based, iron-based and copper-based alloy powders and composite tungsten carbide grades.

How is each batch tested before shipment?

Chemical composition is checked by ICP, oxygen, nitrogen and hydrogen by inert gas fusion, and carbon and sulphur by combustion analysis. Particle size is measured by laser diffraction and sieve, density and flow are recorded, and hardness is tested on consolidated samples. Industrial CT is available for internal defect checks.

Which alloy system suits high-temperature polymer filtration?

Nickel-based and cobalt-based systems are the usual choice where the melt is hot and chemically aggressive. Iron-based grades cover less corrosive duty at lower cost, and copper-based grades bring thermal conductivity into the pack.

What do you need to prepare a quotation?

Polymer type, melt temperature, target filtration fineness, allowable pressure drop, pack geometry and fill volume, preferred alloy system, particle size cut, annual volume, packaging format and any documentation requirements.

Do you support custom cuts and blended chemistries?

Yes — custom particle size cuts, blended chemistries and pure metal powders are produced to specification, with the analysis recorded against the batch.