Análisis de metales

Soluciones analíticas para análisis de metales y fabricación de aleaciones

Lo ayudamos a satisfacer la demanda, volverse más sostenible y a hacer que los procesos sean más fáciles, más limpios y más seguros. Con un análisis que lo ayudará a encontrar nuevas posibilidades. Nuestros instrumentos, nuestras soluciones automatizadas, nuestros servicios y nuestra experiencia, líderes en el mundo, lo ayudarán a configurar el control de procesos y el control de calidad deseados en la industria de los metales, ya sea que se trate de metales primarios o productos especiales.


En entornos de alto rendimiento y sensibles al tiempo en las industrias del hierro, acero, aluminio, cobre y titanio, el control de procesos y el control de calidad son esenciales. Como tal, los productores de metales deben poder analizar con rapidez y exactitud la estructura, el tamaño y la forma de las partículas, y la densidad de sus sustancias químicas, metales y aleaciones.

Types of metal material analysis

Aluminum

From bauxite to alumina and aluminum, rapid and precise monitoring of material streams is key in the aluminum analysis process. By monitoring process-relevant parameters, manufacturers can achieve their commercial targets and maintain process efficiency while also mastering the transition to CO2-free metal production. With Malvern Panalytical’s industrial solutions, you can analyze mineralogical (Aeris Metals) and elemental composition (Axios FAST, Metals edition of Zetium) and particle size and shape (Mastersizer 3000), as well as directly predict process parameters such as the available alumina in bauxite, the structural modifications of alumina, bath composition during aluminum smelting, and the impurities, stress, and texture of aluminum metal or alloys. Our solutions range from real-time analysis instruments (e.g., CNA cross belt analyzer, Epsilon Xflow, and Insitec) to fully automated laboratories.

Iron production

Rapid, accurate monitoring of material streams is mandatory throughout the iron and steel-making process. Manufacturers must track process-relevant parameters to achieve their commercial targets and maintain process efficiency, while at the same time mastering the transition to CO2-free steel production. Malvern Panalytical’s industrial solutions enable you to analyze raw materials, as well as intermediate products such as iron sinter, iron ore pellets, and direct reduced iron (DRI), and final products like steel or steel alloys. Our solutions monitor mineralogical (Aeris Metals) and elemental composition (Axios FAST, Metals edition of Zetium), as well as particle size and shape (Mastersizer 3000). They can also directly predict process parameters such as the FeO content, the physical parameters of sinter and pellets, metallization and impurities, stress, and texture in steel and steel alloys. Our solutions range from instruments for real-time analysis (e.g., CNA cross-belt analyzer and Insitec) to fully automated laboratories.

Non-ferrous metal production

As non-ferrous metals manufacturers work to achieve their commercial targets and transition to CO2-free metal production, fast and precise monitoring is critical in their production processes. From ores to copper, nickel, and zinc steel alloys, frequent monitoring of the various material streams is essential to ensuring maximum process efficiency. Malvern Panalytical’s industrial solutions enable you to analyze raw materials, intermediate products such as leachate or metal liquors, and final metal or metal alloy products. Our solutions monitor mineralogical (Aeris Metals) and elemental (Axios FAST, Metals edition of Zetium) composition, as well as particle size and shape (Mastersizer 3000). They can also directly predict process-relevant parameters such as the efficiency of solvent extraction and electrowinning, slag composition, and the stress and texture of metals and metal alloys. Our solutions range from real-time analysis instruments (e.g., CNA cross belt analyzer, Epsilon Xflow, and Insitec) to fully automated laboratories.

Metal coatings

Manufacturers of metal coatings rely on frequent monitoring during the production process to achieve their quality and commercial targets while maximizing process efficiency. As the industry transitions toward CO2-free metals production, this analysis is only becoming more crucial. During the various coating processes such as galvanizing or galvannealing, rapid and precise monitoring to ensure quality and process efficiency are mandatory. Malvern Panalytical’s industrial solutions enable process optimization through efficient analysis, ensuring that quality specifications are met. Our instruments monitor the mineralogical and elemental composition of metal coatings, with solutions ranging from real-time analysis to fully automated laboratories.

Metal powders

Consistently producing metal components or products with the correct properties requires input materials with reliable characteristics that you understand fully. For metal powders, these characteristics can include chemical, morphological, and microstructural properties that must be measured using the appropriate analysis techniques. Particle size and shape are key properties in most metal powder processes since they impact powder flow, powder packing, porosity, reactivity, and even health and safety. Chemistry is also paramount, especially for powder metallurgy and additive manufacturing, in which powder needs to comply with the alloy composition of the material specified. The crystallographic structure can affect the mechanical and chemical properties of metal powders and fabricated components alike.

Our key solutions for particle characterization are the Mastersizer 3000 and Morphologi 4, which are highly automatable benchtop instruments. For metal nanoparticles and dispersions, our Zetasizer range offers a more appropriate solution.

Our floor-standing (Zetium) and compact (Epsilon) X-ray fluorescence spectrometers both provide elemental analysis, depending on application requirements. For structural and crystallographic studies, X-ray diffraction (XRD) is our principal solution and is also available in both floor-standing ( Empyrean) and compact (Aeris) system formats.

Sostenibilidad de los metales

Nuestra crisis climática se está volviendo cada vez más apremiante, y los metales desempeñarán un papel clave en la lucha contra ella. Con estos desafíos y estas oportunidades en mente, los productores de metales están trabajando arduamente para cumplir con los objetivos medioambientales, como el acero sin CO2. Nuestras innovadoras soluciones de caracterización de metales respaldan estos esfuerzos, lo que le permite monitorear cuidadosamente sus materiales y procesos, impulsar la eficiencia, minimizar el desperdicio de materiales y el uso de energía, y evitar la contaminación tóxica.

Mastersizer 3000

Entregamos los datos que necesita para obtener resultados confiables
Mastersizer 3000

Axios FAST

Alto rendimiento de muestras
Axios FAST

Empyrean

El difractómetro inteligente
Empyrean

XRD in metal analysis

Metals manufacturing relies on excellent analysis, and understanding the mineralogical and structural properties of materials is essential to high-quality results. In high-throughput industrial processes such as iron production, efficiency is key – but structural analysis has historically relied on wet chemical and physical methods. These can be time- and labor-intensive, and are not well-suited to a busy industrial setting. 

X-ray diffraction (XRD) analysis overcomes this challenge by providing direct prediction of process parameters at a much higher throughput rate than older techniques, with the possibility of automation improving efficiency even further. In combination with elemental analysis, XRD provides additional insights into material streams – enabling more robust process control and bringing more sustainable production within reach. 

An example of how XRD can contribute to a greener metals industry is its application in the characterization of direct reduced iron (DRI), which will play a key role in the steel production of the future. It also offers an efficient solution for monitoring electrolytic baths during aluminum production. Laboratory X-ray diffractometers, such as our Empyrean range, are often used to analyze retained austenite, stress and texture during steel production.

Trace element analysis in metals

Trace elements can alter the final properties of metals in unpredictable ways. If trace elements are not monitored and controlled, they can cause defects in the finished product that may have serious consequences if the metal part fails or performs unreliably. For this reason, metals manufacturers need to closely monitor the trace element content in their metals. As customers require ever higher performance, steelmakers have had to improve their melting operations to control many chemical elements at levels of 50 ppm or below. The best method for monitoring elemental composition with this level of accuracy is X-ray fluorescence (XRF) analysis.

Control of trace substances has led to improvements in mechanical characteristics at various temperatures, toughness and fracture mechanics at low temperatures, weldability, hot and cold formability, and corrosion resistance. All these are essential performance parameters – so it’s clear that XRF adds real value to almost any metal production process.

At Malvern Panalytical, we are proud of our decades of experience in providing XRF analytical instruments to the metals industry – and proud to be helping so many of our customers manage the transition to a more sustainable and automated future in metals. 

The innovative sensor design of our instruments and our tailored solutions add value across the evolving industry, and our expert application specialists are always available to support and assist our customers.

Soluciones automatizadas de procesamiento de metales

El impulso hacia la producción automatizada de metales se vuelve más fuerte cada día, lo que permite a los investigadores, fabricantes y trabajadores de minas de minerales metálicos operar de manera más independiente, eficiente y segura. Esto se debe a que los procesos automatizados permiten realizar un monitoreo mucho más frecuente, incluso en entornos remotos. En Malvern Panalytical, permitimos que los productores de metales se muevan hacia las operaciones automatizadas con nuestras soluciones de pruebas de laboratorio automatizadas.

  • Soluciones de automatización
  • Soluciones automatizadas de control de procesos

El laboratorio automatizado

Vea nuestro video para conocer las ventajas de un laboratorio automatizado:

Monitoree más rápido con parámetros estrictos: soluciones en línea

A medida que aumentan las presiones regulatorias, competitivas y de costos, la eficiencia es más esencial que nunca para los productores de metales. Gracias a un control rápido y preciso de los parámetros críticos, el monitoreo en tiempo real de las materias primas y de los flujos de proceso puede ayudar a ahorrar tiempo, reducir los desperdicios y garantizar el cumplimiento de las especificaciones más estrictas del producto. 

Nuestras soluciones en línea, incluidos los analizadores de líquidos y de banda en línea para la entrada de hornos altos, facilitan este monitoreo en tiempo real.

Epsilon Xflow

Información directa en sus procesos de producción
Epsilon Xflow

Gama de equipos CNA

Analizadores elementales en línea para el control de procesos industriales
Gama de equipos CNA

Rango de equipos Insitec

Sólido, confiable, medición de tamaño de partículas en tiempo real
Rango de equipos Insitec