Abstract: An apparatus efficiently preparing ultrafine spherical metal powder includes a housing, a crucible and a powder collection area arranged in the housing. The turnplate arranged in the powder collection area is an inlaid structure. The part inlaid into the body part acts as an atomization plane of the turnplate. The atomization plane is provided with a concentric circular groove, and the turnplate is provided with an air hole. The apparatus is used for preparing ultrafine spherical metal powder by on-by-one droplets centrifugal atomization method, mainly combining the uniform droplet jet method and the centrifugal atomization method, which breaks through the traditional metal splitting model, makes the molten metal in a fibrous splitting, so as to efficiently prepare ultrafine spherical metal powder with narrow particle size distribution interval, high sphericity, good flowability, excellent spreadability, uniform and controllable size, no satellite droplets and suitable for industrial production.

Abstract: A method of manufacturing a polarizing glass sheet includes subjecting, while heating, a glass preform sheet containing metal halide particles to down-drawing, to thereby provide a glass member having stretched metal halide particles dispersed in an aligned manner in a glass matrix, and subjecting the glass member to reduction treatment to reduce the stretched metal halide particles, to thereby provide a polarizing glass sheet. A shape of the glass preform sheet during the down-drawing satisfies a relationship of the following expression: L1/W1?1.0 where L1 represents a length between a portion in which a width of the glass preform sheet has changed to 0.8 times an original width and a portion in which the width of the glass preform sheet has changed to 0.2 times the original width W0, and W1 represents a length equivalent to 0.5 times the original width W0 of the glass preform sheet.

Abstract: Provided is a group of rare-earth regenerator material particles having an average particle size of 0.01 to 3 mm, wherein the proportion of particles having a ratio of a long diameter to a short diameter of 2 or less is 90% or more by number, and the proportion of particles having a depressed portion having a length of 1/10 to ½ of a circumferential length on a particle surface is 30% or more by number. By forming the depressed portion on the surface of the regenerator material particles, it is possible to increase permeability of an operating medium gas and a contact surface area with the operating medium gas.

Abstract: The present invention provides a method for producing nanometer-size spherical particles. The method includes a first step for producing intermediate spherical particles. The intermediate spherical particles include a polycrystalline or single-crystalline region, having a particle size of 1 to 300 ?m. The method of the present invention further includes a second step for producing final spherical particles. The second step uses a swirling plasma gas flow having the central axis thereof, the central axis running through an area between an anode and a cathode of a plasma generator. The intermediate spherical particles are discharged along the axis to subject the intermediate spherical particles to a plasma atmosphere of the area to form the final spherical particles.

Abstract: The present invention provides a method for producing nanometer-size spherical particles. The method includes a first step for producing intermediate spherical particles. The intermediate spherical particles include a polycrystalline or single-crystalline region, having a particle size of 1 to 300 ?m. The method of the present invention further includes a second step for producing final spherical particles. The second step uses a swirling plasma gas flow having the central axis thereof, the central axis running through an area between an anode and a cathode of a plasma generator. The intermediate spherical particles are discharged along the axis to subject the intermediate spherical particles to a plasma atmosphere of the area to form the final spherical particles.

Abstract: An apparatus for forming particles from a liquid, including a rotor assembly having at least one surface sized and shaped so as to define at least one capillary. Each capillary has an inner region adjacent an axis of rotation of the rotor assembly, an outer region distal from the axis of rotation, and an edge adjacent the outer region. The rotor assembly is configured to be rotated at an angular velocity selected such that when the liquid is received in the inner region of the at least one capillary, the liquid will move from the inner region to the outer region, adopt an unsaturated condition on the at least one surface such that the liquid flows as a film along the at least one surface and does not continuously span the capillary, and, upon reaching the edge, separates from the at least one surface to form at least one particle.

Abstract: The invention concerns alloyed zinc powders for alkaline batteries and a method to manufacture such powders. The powders are characterized by the presence of particles pierced with at least one hole. This appears to benefit the high drain discharge capacity while preserving the process ability of the powder, and the shelf life and the gassing behavior of the batteries. The invented powders can be manufactured using centrifugal atomization in a cooled, oxygen-depleted atmosphere.

Abstract: Provided is a group of rare-earth regenerator material particles having an average particle size of 0.01 to 3 mm, wherein the proportion of particles having a ratio of a long diameter to a short diameter of 2 or less is 90% or more by number, and the proportion of particles having a depressed portion having a length of 1/10 to ½ of a circumferential length on a particle surface is 30% or more by number. By forming the depressed portion on the surface of the regenerator material particles, it is possible to increase permeability of an operating medium gas and a contact surface area with the operating medium gas.

Abstract: A centrifugal impact atomization process for producing zinc or zinc alloy powder from molten zinc. A stream of molten zinc is injected onto the surface of a spinning disk contained within an atomization chamber. The disk has a cup shaped cavity having an open end, opposing closed end and integral side walls. The disk may have baffles protruding into the open cavity core within the disk. The baffles may have straight or curved side surfaces. The disk is rotated at high speeds between about 10,000 and 15,000 rpm (revolutions per minute). The oxygen content in the chamber is preferably between about 1 and 6 vol %. Zinc powder is produced having more smaller size particles. Zinc alkaline cells utilizing such zinc product as anode active material show improved performance, especially as power source in high discharge services such as digital cameras.

Abstract: The present invention provides a method for producing nanometer-size spherical particles. The method includes a first step for producing intermediate spherical particles. The intermediate spherical particles include a polycrystalline or single-crystalline region, having a particle size of 1 to 300 ?m. The method of the present invention further includes a second step for producing final spherical particles. The second step uses a swirling plasma gas flow having the central axis thereof, the central axis running through an area between an anode and a cathode of a plasma generator. The intermediate spherical particles are discharged along the axis to subject the intermediate spherical particles to a plasma atmosphere of the area to form the final spherical particles.

Abstract: A centrifugal impact atomization process for producing zinc or zinc alloy powder from molten zinc. A stream of molten zinc is injected onto the surface of a spinning disk contained within an atomization chamber. The disk has a cup shaped cavity having an open end, opposing closed end and integral side walls. The disk may have baffles protruding into the open cavity core within the disk. The baffles may have straight or curved side surfaces. The disk is rotated at high speeds between about 10,000 and 15,000 rpm (revolutions per minute). The oxygen content in the chamber is preferably between about 1 and 6 vol %. Zinc powder is produced having more smaller size particles. Zinc alkaline cells utilizing such zinc product as anode active material show improved performance, especially as power source in high discharge services such as digital cameras.

Abstract: Methods, apparatuses and systems for producing powder particles of extremely small, highly uniform spherical shape and high sphericity, composed of metal including single metals and alloys, including nanocomposite structures, using a self-assembling procedure. The invention further includes the produced spherical particles. The metal spherical particles are produced whereby molten metal, alloys or composites are directed onto a fast-rotating disk in an atmosphere containing one or more inert gases and small amounts of an oxidizing gas and the molten metal drops are dispersed as tiny droplets for a predetermined time using centrifugal force within a cooling-reaction gas, and then cooled rapidly to form solid spherical particles. The spherical particles comprise a crystalline, amorphous or porous composition, having a size of 1-300 ?m±1% with a uniformity of size being ?60-70% and a precise spherical shape of less than or equal to ±10%.

Abstract: This invention relates to centrifugal atomized zinc alloy powders for alkaline batteries consisting of (a) 0.005-2% by weight of indium, and 0.005-0.2% by weight of either one of Al and Bi, or (b) 0.005-2% by weight of indium, and 0.005-0.2% by weight of Bi, and 0.001-0.5% of either one or both of Al and Ca, or (c) 0.005-2% by weight of either one or both of Bi and Al, and 0-0.5% by weight of Pb, the remainder being zinc. The powder is obtained by centrifugal atomisation in a protective atmosphere, where the oxygen content is less than 4% by volume. The resistance to corrosion in the electrolyte of the battery, especially after partial discharge, is markedly better than when the same alloys are prepared by the traditional production process. The capacity of batteries containing these powders is very good.

Abstract: This disclosure relates to a novel process for atomizing a liquid material or a mixture of liquid materials. More specifically, this disclosure advances the art by utilizing the inertial forces created in an elevated acceleration environment to further miniaturize and enhance the characteristics of particles resulting from atomization. The key to this disclosure is to subject a melt material to an elevated acceleration and pass a fluid over the surface of the melt. The purpose of the elevated acceleration is to elevate the relative importance of gravitational forces in the melt thus miniaturizing any gravity influenced disturbance. This elevated acceleration environment leads to miniaturization of gravitationally dependent phenomena thus leading to smaller particle creation. The purpose of the atomizing fluid is to impart kinetic energy onto the melt thereby causing disturbances and to act as a heat transfer media to cool the particles.

Abstract: Disclosed herein is a method of manufacturing a magnetic material which can provide a bonded magnet having excellent magnetic properties and having excellent reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 in which gas expelling grooves 54 are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 6 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas expelling grooves 54.

Abstract: A magnetic material manufacturing method, a ribbon-shaped magnetic material manufactured by the method, a powdered magnetic material formed from the ribbon-shaped magnetic material and a bonded magnet manufactured using the powdered magnet material are disclosed. The method and the magnetic materials can provide magnets having excellent magnetic properties and reliability. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5 having a circumferential surface 53 on which dimple correcting means is provided. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5 in an inert gas atmosphere (ambient gas) such as helium gas, so that the molten alloy 6 is cooled and then solidified.

Abstract: A manufacturing method of minute metallic spheres of the present invention comprises a heating means for heating and melting a metal to form a metallic sphere, a measurement means for measuring the injected molten metal into a predetermined volume, and a cooling means for cooling the molten metal discharged from the measurement means, to a temperature less than the melting point. The measurement means has a gauger of a predetermined volume in which the molten metal is injected, and is constructed such that the molten metal is cut by rubbing by the predetermined volume by sliding this gauger in contact. The molten metal is injected in the gauger of the predetermined volume to measure, and the measured molten metal is discharged from the gauger to cool to a temperature less than the melting point, and solidified into a sphere in the cooling process.

Abstract: Methods, apparatuses and systems for producing powder particles of extremely small, highly uniform spherical shape and high sphericity, composed of metal including single metals and alloys, including nanocomposite structures, using a self-assembling procedure. The invention further includes the produced spherical particles. The metal spherical particles are produced whereby molten metal, alloys or composites are directed onto a fast-rotating disk in an atmosphere containing one or more inert gases and small amounts of an oxidizing gas and the molten metal drops are dispersed as tiny droplets for a predetermined time using centrifugal force within a cooling-reaction gas, and then cooled rapidly to form solid spherical particles. The spherical particles comprise a crystalline, amorphous or porous composition, having a size of 1-300 &mgr;m±1% with a uniformity of size being ≦60-70% and a precise spherical shape of less than or equal to±10%.

Abstract: A method of fabricating a thermoelectric element of enhanced thermoelectric performance is provided by improving the preparation of thermoelectric material and employing hot plastic working in combination. The method comprises the step (a) of mixing and heat-melting a raw material of a predetermined composition; the step (b) of turning the heat-melted material 106 into microglobules by either of scattering and spraying, and then quenching the microglobules, thereby providing a globular powdery thermoelectric material; and the step (c) of plastically deforming the thermoelectric material in a hot condition, thereby to bring crystal grains of the thermoelectric material into a crystal orientation affording an excellent figure of merit.

Abstract: A method of manufacturing magnetic powder is disclosed. This method can provide magnetic powder from which a bonded magnet having excellent magnetic properties and reliability can be manufactured. A melt spinning apparatus 1 is provided with a tube 2 having a nozzle 3 at the bottom thereof, a coil 4 for heating the tube and a cooling roll 5. The cooling roll 5 is constructed from a roll base 51 and a circumferential surface 53 in which gas flow passages 54 for expelling gas are formed. A melt spun ribbon 8 is formed by injecting the molten alloy 6 from the nozzle 3 so as to be collided with the circumferential surface 53 of the cooling roll 5, so that the molten alloy 6 is cooled and then solidified. In this process, gas is likely to enter between a puddle 7 of the molten alloy 6 and the circumferential surface 53, but such gas is expelled by means of the gas flow passages 54. The magnetic powder is obtained by milling thus formed melt spun ribbon 8.

Abstract: A non-oxide powder of which at least about 40% by mass is comprised of a plurality of tightly agglomerated compositions, each of the tightly agglomerated compositions comprising a plurality of primary particles agglomerated together. Suitable materials for the primary particles include metals, intermetallics, ceramics, MMCs, and non-metals. An encapsulation and scavenging process is used to create the agglomerated compositions wherein at least some of the agglomerated compositions are encapsulated in a secondary material such as a salt or a polymer.

Abstract: Fine powders are made from molten metals and alloys on a continuous basis. A rapidly spinning shallow cup has an atomizing fluid such as water, oil or any other hydrocarbon supplied to the cup to form a thin sheet or layer which is distributed on the inner surface of the cup. Within the cup a stream or spray of molten metal is propelled into this thin sheet of atomizing fluid. The metal interacts with the atomizing fluid film and is fragmented or broken down into many small droplets which are quenched by the atomizing fluid and solidified into fine powder. These powders in the form of a slurry with the atomizing fluid can be continuously removed as the slurry discharges up over the lip of the cup by centrifugal force and the powders can be recovered. In a preferred embodiment a preatomizer is positioned between the incoming stream of molten metal and the spinning cup.

Abstract: A procedure for making zinc particles of a size, shape and composition such that the particles can be subsequently used in a process for manufacturing zinc parts from such particles in either molten or powder form includes the initial step of heating zinc to a temperature at least as high as 720.degree. C. The molten zinc is passed through a screen having small openings, on the order of about 1/4".times.1/4" into a cooling region formed by a movable surface which is at a temperature of on the order of about -200.degree. C. The zinc forms small particles as it passes through the openings in the screen and essentially instantaneously solidifies as it contacts the movable surface. Thereafter, the solidified zinc particles are subjected to a grinding process to reduce their size to a powder having a surface area in the range of 2 mm.sup.2 to 20 mm.sup.2.

Abstract: A system and method for producing fine powders. The system includes a rotary atomization device for forming a moving flow of a molten source material; a source of atomizing material; a nozzle for directing a jet of the atomizing material at the moving flow of molten source material for atomizing and for producing fine droplets of the source material; and a chamber for collecting the fine droplets.

Abstract: The yield of flat powder (6) of Al, Mg or their alloy is enhanced by forming, on a rotary cooling body (4), a film (8) which can prevent the flat metal powder (8) from sticking to the cooling surface. The film (8) adheres to the cooling surface at a force which is sufficient for forming the film but which enables the film material to adhere to the flat powder which then separates from the cooling body (4). The film consists essentially of at least one liquid lower fatty acid and at least one solid higher fatty acid.

Abstract: Method and apparatus for making metallic powder particles wherein a metallic melt is atomized by a rotating disk or other atomizer at an atomizing location in a manner to form molten droplets moving in a direction away from said atomizing location. The atomized droplets pass through a series of thin liquid quenching sheets disposed in succession about the atomizing location with each successive quenching sheet being at an increasing distance from the atomizing location. The atomized droplets are incrementally cooled and optionally passivated as they pass through the series of liquid quenching sheets without distorting the atomized droplets from their generally spherical shape. The atomized, cooled droplets can be received in a chamber having a collection wall disposed outwardly of the series of liquid quenching sheets.

Abstract: A granulator comprises a rotary atomizer on to which the molten material to be granulated is poured in a stream. The rotation of the atomizer causes the molten material to be ejected therefrom in the form of globules. No fluid jets are used to break up the molten material. The globules pass through an enclosure and partially freeze to form granules which are collected in an annular trough. A gas is injected into the trough to induce a circumferential movement of the granules within the trough towards at least one exit from the trough.

Abstract: Alloy powder which is low in price and is unlikely to be oxidized on the surface, and a dispersion-type conductor using the alloy powder in which electromigration is not likely to occur. Melt of copper and silver is cooled at a high cooling speed of 10.sup.5 .degree.C./s or higher. Alloy powder having a composition expressed by a chemical formula Cu.sub.x Ag.sub.1-x (where 0.80.ltoreq..times..ltoreq.0.99) is obtained. Also, a dispersion-type conductor is produced by dispersing 100 parts by weight of the alloy powder in between 5-100 parts by weight of a binder. Thus, the low-priced alloy powder and the dispersion-type conductor of high quality and high reliability can be obtained.

Abstract: A dispersion-strengthened copper alloy is disclosed having an exceptional combination of strength, ductility, and thermal conductivity. The copper alloy comprises: copper, 0.01 to 2.0 weight % boron and 0.1 to 6.0 weight % cobalt, and cobalt-boride disperoids that range in size between 0.025 and 0.25 microns in diameter. A copper alloy is made by rapid solidification of the melt into a powder. Strong, thermally conductive articles can be made by compacting the powder at temperatures below the melting temperature of the copper alloy, and optionally warm working, cold working, and annealing.

Abstract: A process for manufacturing an Alnico system permanent magnet is disclosed in which the alloy powder of the Alnico system having the proper composition is manufactured through a rapid solidification process, so that the crushability and the formability should be superior, the sintered density should be high, and the magnetic properties should be excellent, as well as cheap in its manufacturing cost and simple in its manufacturing process. An alloy of Alnico system is subjected to a rapid solidification with a spinning solidifier wheel speed of 6-40 m/sec, thereby manufacturing a microcrystalline rapidly solidified powder. The powder is ground into a finer powder, and then a press-forming is carried out. Then a sintering is carried out at a temperature of 1100.degree.-1350.degree. C. for 0.5-4 hours. Then based on a single heat treatment, an external magnetizing force of 1-15 kOe is applied in a temperature range of 600.degree.-1000.degree. C., thereby carrying out a heat treatment under a magnetizing force.

Abstract: A granulator comprises a rotary atomiser (1) on to which the molten material to be granulated is poured in a stream. The rotation of the atomiser (1) causes the molten material to be ejected therefrom in the form of globules. No fluid jets are used to break up the molten material. The globules pass through an enclosure (6) and partially freeze to form granules which are collected in an annular trough (10). A gas is injected into the trough (10) to induce a circumferential movement of the granules within the trough towards at least one exit from the trough (10).

Abstract: Apparatus for producing metal powders by atomization, the apparatus including melting means for melting the material to be atomized, an atomizing enclosure in which a dispersion head rotating at high speed is disposed to scatter the molten material in atomized form, means for cooling the atomized material and the head, and means for collecting the cooled powder material obtained in this way, said melting means including at least one vertical inductive plasma furnace producing an envelope of plasma-generating gases containing the top face of the dispersion head, and said cooling means comprising both a first series of members for dispensing a cooling fluid disposed in the top portion of the atomizing enclosure to create a cold zone at the periphery of the envelope, and a second series of members for circulating a cooling fluid disposed in the bottom portion of the enclosure to create a cold zone at the bottom face of the head.

Abstract: The method for preparing metal powders with a narrow particle size distribution includes providing a disintegrator with a working chamber containing counter-rotating disks equipped with teeth designed to impart high tangential velocities to particles contacting the teeth, introducing a metal melt as a liquid stream with a composition substantially corresponding to the final metal powder composition into the working chamber of the disintegrator, counter-rotating the disks, whereby the liquid stream of metal entering the chamber is broken up into small beads, which leave the surface of the teeth with high velocities, and whereby subsequent contact of the beads with the teeth of the disks further break up the liquid beads until the bead solidifies by heat loss to the disks and collecting a fine metal powder of narrow particle size distribution at the exit end of the working chamber.

Abstract: Disclosed is a method and an apparatus for producing rapidly-solidified flake particles, which combines centrifugal atomization with metal substrate cooling. A stream of molten metal is disintegrated centrifugally into droplets by a rotating disk. Then the molten droplets are solidified as flake particles as soon as impinging upon the annular planar surface of a cooled rotating concave disk. The solidified flake particles are subsequently departed from the annular planar surface by the centrifugal force and collected in a chamber.

Abstract: The present invention provides an additive powder for coating materials or plastics, comprising a particle of a metal or glass, comprised of a particle having a thickness of 0.5 to 5 .mu.m, a minor axis/major axis of from 5 to 500 .mu.m, an aspect ratio (ratio of the major axis to the thickness) of not less than 5, and a ratio of the minor axis to the major axis, of from 1 to 10, and having the shape of a leaf as a whole. This powder can be prepared by melting a metal or glass, bringing the resulting melt to flow out from a nozzle and jetting a gas to the melt to form droplets of the melt, and bringing said droplets, before they solidify, to collied against the surface of a rotating cooling member having the shape of an cone or horn and provided in the directio of the flow of said droplets, followed by cooling to effect solidification.

Abstract: Producing finely divided U.sub.3 Si by supercooling a melt of uranium and silicon at a high cooling rate of 10.sup.3 to 10.sup.7 .degree. C./sec.

Abstract: This invention describes a process for producing copper alloys by rapid sdification in order to improve their strength and thermal stability after being exposed to elevated temperatures. The method used to rapidly solidify the molten alloy is either by use of a high pressure non-oxidizing gas spray to atomize the molten alloy into a powder or to pour the molten alloy onto a rotating wheel to form a ribbon which is then attrited into powder. The powder is canned, compacted to full density and cold worked to the desired shape.