Abstract: A method of producing passivated Ti or Ti alloy particles with oxygen concentrations of less than about 900 parts per million (ppm), which includes introducing a halide vapor of Ti or the metal constituents of the alloy at sonic velocity or greater into a stream of liquid alkali or liquid alkaline earth metal or mixtures thereof forming a reaction zone in which the halide is reduced by the liquid metal present in sufficient excess of stoichiometric such that Ti or Ti alloy powder from the reduction of the halide by the liquid metal is friable. After filtration and distillation excess liquid metal is removed from the Ti or Ti alloy powder that is then maintained at elevated temperature for a time sufficient to grow the particles to average diameters calculated from BET surface area measurement greater than about one micron. After cooling the Ti or Ti alloy powder to temperature of about 80° C.

Abstract: A method of separating metal particulates from a slurry of original constituents of liquid metal and metal particulates and salt particulates is disclosed. The metal and salt particulates are concentrated by removing at least some of the liquid metal, and then, liquid metal or a liquid of the original salt constituent or a mixture thereof is passed through the particulates at a temperature greater than the melting point of the original salt constituent to further concentrate the metal particulates. The metal particulates are then separated from the remaining original constituents or a mixture of the salt constituent. Density differences between the liquid metal and salt are also used to facilitate separation.

Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.

Abstract: A needle valve is disclosed for controlling the quantity of a halide vapor to be injected into a liquid metal. The needle valve may seat in a supersonic nozzle from which the halide vapor exits. Various products made with the apparatus of the invention are disclosed.

Abstract: A system and method of separating metal powder from a slurry of liquid metal and metal powder and salt is disclosed in which the slurry is introduced into a first vessel operated in an inert environment when liquid metal is separated from the metal powder and salt leaving principally salt and metal powder substantially free of liquid metal. The salt and metal powder is transferred to a second vessel operated in an inert environment with both environments being protected from contamination. Then the salt and metal powder are treated to produce passivated powder substantially free of salt and liquid metal. The method is particularly applicable for use in the production of Ti and its alloys.