Abstract: The present invention is for a device for rapidly solidifying a material and a method of using the same. The device provides for containing a molten pool of material in a solid skull with the same composition as the molten material. The skull is preferably held in a cavity of an inductor which is heated by an induction coil. Means are provided to maintain a small temperature gradient in the skull so as to minimize segregation which can lead to compositional fluctuations. It is preferred that the minimum temperature in the skull is between about 0.7 and 0.95Tm, where Tm is the melting or solidus temperature of the material.Feed means provide material to the molten pool causing it to spill over onto a moving chill surface. Preferably the chill surface is cooled by a molten stream of liquid gas.

Abstract: The present invention is directed to a method and the associated apparatus for producing rapidly solidified materials by spill chilling. The feed stock can include any of a variety of materials including a high melting point and reactive materials, as well as conventional iron, aluminum, copper and transition base commercially available alloys. A support surface is provided for the solid feed material. Means are provided for both globally and locally heating the feed material. The heating means can include resistant heaters, induction heaters, arcs, electron beam and plasma heaters. A focused energy source such as an electron beam, a laser beam, ion beam or an electric arc can be provided for locally heating the material. The molten feed material is spill chilled onto a moving chill surface. The moving chill surface can be in the form of a continuous belt or the rim of a rotating wheel.