Abstract: A system for making a material having domains with insulated boundaries is provided. The system includes a droplet spray subsystem configured to create molten alloy droplets and direct the molten alloy droplets to a surface, a gas subsystem configured to introduce one or more reactive gases to an area proximate in-flight droplets. The one or more reactive gases creates an insulation layer on the droplets in flight such that the droplets form a material having domains with insulated boundaries.

Abstract: A molten metal temperature control method includes: with respect to relations among a spheroidization distance traveled by a molten metal of an alloy from a nozzle tip to a position where the molten metal turns into droplets, the temperature of the molten metal inside the crucible, and a pressure acting on the molten metal inside the crucible, obtaining a relation between the temperature and the spheroidization distance at a predetermined pressure, and setting a predetermined temperature range of the temperature; measuring a spheroidization distance when discharging the molten metal from the crucible at the predetermined pressure, and specifying a temperature corresponding to the measured spheroidization distance; and comparing the specified temperature and the predetermined temperature range, and when the specified temperature is outside the predetermined temperature range, controlling the specified temperature so as to be within the predetermined temperature range by adjusting the temperature inside the cru

Abstract: Devices and methods are provided for ejecting a droplet from a reservoir using focused acoustic radiation having a plurality of nonsimultaneous and discrete frequency ranges. Such frequency ranges may be used to control droplet volume and/or velocity. Optionally, satellite fluid ejection from the reservoir is suppressed.

Abstract: The problem addressed by the present invention is providing a method for producing microparticles. At least two fluids to be processed, a raw material fluid that contains a raw material and a processing fluid that contains a substance for processing the raw material are mixed in a thin film fluid formed between at least two surfaces for processing that are disposed so as to face each other, that can approach and separate from each other and at least one of which rotates relative to the other, and microparticles of the raw material that is processed are obtained. At this time, the proportion of the microparticles of the raw material which has been processed that coalesces with each other is controlled by controlling the circumferential speed of the rotation in a confluence section in which the raw material fluid and processing fluid flow together.

Abstract: Low cost spherical titanium and titanium powder alloy powder is produced by impinging a stream of an inert gas, such as argon, on the surface of a molten pool of titanium or sponge and alloying elements.

Abstract: A solder powder having an average particle diameter of, for example, 0.05 ?m or more and less than 3 ?m is obtained by a method of producing a solder powder, including the steps of: putting solid or liquid metal, a non-aqueous solvent, and crushing balls having a diameter of 0.05 mm to 5 mm into a container to obtain a mixture; heating the mixture to 150° C. or higher and stirring the mixture; separating the crushing balls from the mixture after the stirring to obtain a mixture of the solder powder and the non-aqueous solvent; and performing solid-liquid separation on the mixture of the solder powder and the non-aqueous solvent to obtain a solder powder.

Abstract: Low cost spherical titanium and titanium powder alloy powder is produced by impinging a stream of an inert gas, such as argon, on the surface of a molten pool of titanium or sponge and alloying elements.

Abstract: A titanium halide, preferably titanium tetrachloride, is reacted with suitable reductant, preferably an alkali metal or alkaline earth metal, under ultrasonic excitation in a liquid reaction medium to form nanometer size particles of titanium which may incorporate unreacted reductant. The nanosized titanium particles may be a precursor for nanosized titanium oxide which is formed by oxidizing the titanium, preferably with a low molecular weight alcohol. When the titanium particles incorporate unreacted reductant the oxidation reaction will yield nanometer sized titanates. The nanosized particles, whether titanium oxide or titanates may be extracted by first filtering them from the reaction medium, followed by washing with water to remove any water-soluble reaction products followed by spray drying.

Abstract: A Method for the recovery of the secondary metallurgy (LF) slag from a plant for the production of steel, the method comprising a cooling step of the slag, by means of the passage of air and/or other gas, a breakdown step, a step of extracting the powder, wherein the breakdown step is accelerated by means of forced convection of a cooling fluid and/or another reaction, gas and by means of moving the slag mass by overturning and vibrating support gratings. The overturning and vibrating support gratings are provided inside closed metallic boxes which are connected in series and closed with movable containment partitions to form a treatment module. The breakdown, step is accelerated by means of overturning the slag mass from the support grating of one metallic box to the support grating of an adjoining box.

Abstract: Apparatus to eject on demand discrete hollow microsphere droplets that are characterized by a highly regular and predictable spherical shape, devoid of tails or other irregularities common in the prior art with a selected pure gas contained in the center. With this method and apparatus, droplets may be formed of any suitable material including glass, ceramic, plastic, or metal. A variety of gases at various pressures including complete vacuums may be contained in the hollow microsphere. Microspheres filled with ionizable gas may be used as pixels in a plasma display panel. Microspheres used as a pixel elements may be referred to as Plasma-spheres. The inside of each Plasma-sphere may contain a luminescent material such as a phosphor and/or a secondary electron emission material such as magnesium oxide or a rare earth oxide introduced during the gas filling of the microsphere.

Abstract: A method of stabilizing lithium metal powder is provided. The method includes the steps of heating lithium metal to a temperature above its melting point, agitating the molten lithium metal, and contacting the lithium metal with a fluorination agent to provide a stabilized lithium metal powder.

Abstract: Nanometer sized particles containing titanium and platinum are prepared by a sonochemical process. Compounds of the metals are dissolved, suspended, or diluted in a low vapor pressure liquid medium, preferably at a sub-ambient temperature. A reducing gas is bubbled through the liquid as it is subjected to cavitation to affect the reductive decomposition of the metal compounds. Titanium and platinum are co-precipitated in very small particles.

Abstract: The method of the present invention can 1) produce spherical and scaly ultrafine particles without pulverization, 2) obtain spherical ultrafine particles having a sharp spherical particle diameter distribution without requiring a sieving step, 3) produce spherical ultrafine particles extremely approximating a true circle and possessing a particle diameter of 100 nm˜50,000 nm allowing selection of a size suitable for the particular purpose of use and 4) produce spherical ultrafine particles on a commercial scale at low cost. There is also provided spherical ultrafine particles produced by the above production process. The spherical ultrafine particles of the present invention are characterized by a form having circularity of 0.9 to 1.0 and a particle diameter of 0.01 ?m to 10 ?m without pulverization. The spherical ultrafine particles can be produced by the method of the present invention using as a nozzle a base having special through holes and hole density.

Abstract: Method for refining and homogeneously distributing alloying partners and for removing undesired reaction products such as oxides and/or slag in or from soft solder during the production of fine solder powder, in which the solder alloy is melted in a high temperature-resistant plant and/or animal oil, the melt is moved to another container of oil with a temperature of at least 20° C. greater than the liquidus temperature, stirred there, and subjected to multiple shear treatments using rotors and stators for forming a dispersion comprising solder balls and oil, from which dispersion the solder balls are separated by means of subsequent sedimentation.

Abstract: A method for the production of solid particles from a liquid medium includes the steps of forming a liquid film between an impact screen and an impact mass, the screen having an opening therethrough, moving the impact mass to effect a mechanical impulse on the film, such that a part of the film is discharged through the opening in droplet form. The discharged liquid droplets are moved to a solidification medium wherein the liquid droplets are solidified to form solid particles.

Abstract: The invention relates to a process and a device (1) for the production of spherical metal particles (2) from a melt (3). In order to produce droplets a melt jet (8) is subjected to vibrations and is led through at least one nozzle (7). In order to produce spherical metal particles (2) the droplets at the outlet of the nozzle (7) are fed to a coolant (10) for purposes of consolidation. The nozzle (7) dips into the coolant (10), the temperature of the coolant (10) being below the melting point of the melt (3).

Abstract: A method for forming a dispersion-strengthened material containing nanoparticles that are uniformly dispersed in a matrix phase. The method includes adding nanoparticles and a molten material to a container to form a pool within the container and rotating the container to create a convection vortex in the pool. The convection vortex is sufficient to cause the nanoparticles to be incorporated into the molten material so as to yield a molten composite material, and further causes the molten composite material to be ejected from the container. The molten composite material is then cooled to form a solid composite body comprising a uniform dispersion of the nanoparticles.

Abstract: A method for forming a nanocomposite material and articles made with the nanocomposite material are presented.

Abstract: A solder jet apparatus is disclosed The solder jet apparatus is a continuous mode solder jet that includes a blanking system and raster scan system. The use of the raster scan and blanking systems allows for a continuous stream of solder to be placed anywhere on the surface in any desired X-Y plane. This allows for greater accuracy as well as greater product throughput. Additionally, with the raster scan system, repairs to existing soldered surfaces can be quickly and easily performed using a map of the defects for directing the solder to the defects.

Abstract: Metal-carbon composite powders and methods for producing metal-carbon composite powers. The powders have a well-controlled microstructure and morphology and preferably have a small average particle size. The method includes forming the particles from an aerosol of powder precursors. The invention also includes novel devices and products formed from the composite powders.

Abstract: The invention relates to a process and a device (1) for the production of spherical metal particles (2) from a melt (3). In order to produce droplets a melt jet (8) is subjected to vibrations and is led through at least one nozzle (7). In order to produce spherical metal particles (2) the droplets at the outlet of the nozzle (7) are fed to a coolant (10) for purposes of consolidation. The nozzle (7) dips into the coolant (10), the temperature of the coolant (10) being below the melting point of the melt (3).

Abstract: The invention relates to a method for the leaching of solid matter from a sludge with the aid of a gas containing oxygen, whereby the solid matter of the sludge is recirculated in a tall reactor equipped with a central pipe in the centre of the reactor and a double-action mixer located in the vicinity of the lower edge of the central pipe. A flow is formed with the aid of the mixer which sucks the sludge from the central pipe downward, and a gas to be conducted into the sludge in the bottom part of the reactor is dispersed in the form of small bubbles into the sludge outside the central pipe and the flow direction of the sludge is turned upwards in the outer casing of the reactor.

Abstract: The invention relates to a method for the production of solid particles from a liquid starting material, whereby a dosed liquid particle is separated from a liquid film by means of transmission of a mechanical impulse thereto and is fed to a region in which the fluid particle is fixed and devices for carrying out said method. Said devices comprise an impulse diaphragm, an impulse mass, at least one opening for the ejection of the liquid particle, means for forming a fluid film on the surface of the impulse diaphragm, whereby the impulse diaphragm or the impulse mass are embodied as a movable actuator for the transmission of an impulse to the liquid film, an impulse drive for the generation of a high frequency force impulse and a high voltage device for guiding the ejected liquid particle along a spiral path.

Abstract: A method of preparing a nanoparticle having a particle size of 1 nm to 1 &mgr;m, said method comprising continuously supplying a solution containing a particle-forming precursor into a micro channel having a diameter of 1 &mgr;m to 1 mm, said micro channel being disposed in a heating zone. The solution is heated rapidly up to a reaction initiation temperature to cause a reaction in said solution. The solution is rapidly cooled to prepare the nanoparticle.

Abstract: Spherical balls, notably microballs of welding alloys, are produced by passing a melted material through vibrating orifices of a granulation pot, in order to form droplets which solidify when falling, by gravity, into a cooling tower filled with an inert gas. To improve the surface condition of the balls, the inert gas comprises approximately 15 to 150 ppm of oxygen. Moreover, the melted material is subject to ultrasound stirring just before being fed into the granulation pot. The balls are, preferably, dampened at the outlet of the cooling tower by brushes composed of polyamide wires. Besides, the control of the vibration frequency of the vibrating orifices in relation to the percentage of balls meeting the standards enables to improve the output.

Abstract: In a high-speed fabrication process for producing highly uniform metallic microspheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. To achieve high uniformity of the spheres and avoid defects, the droplets are cooled before being captured. Separating the droplets, by causing them to travel in different paths than their adjacent droplets, helps to facilitate the cooling of the droplets. The droplets can be separated by electrostatically charging them as they break off from the capillary stream. The droplets are then passed through an electric field, which can be produced by a pair of deflection plates. The droplets are dispersed by varying the electric field—e.g., by rotating the plates or by varying the voltage applied thereto—or by varying the electrostatic charge of the droplets.

Abstract: A solder ball having a diameter of 1.2 mm or less, a dispersion of a diameter distribution of 5% or less and sphericity of 0.95 or more, an area ratio of the maximum dendrite being 80% or less of a cross section including a center of the solder ball, comprises a first additional element of 0.5-8 mass % of Ag and/or 0.1-3 mass % of Cu, and 0.006-10 mass %, in total, of at least one second additional element selected from the group consisting of Bi, Ge, Ni, P, Mn, Au, Pd, Pt, S, In and Sb, the balance being substantially Sn. The solder ball is produced by a uniform droplet-spraying method comprising the steps of vibrating a melt of a solder alloy in a crucible under pressure to force the melt to drop through orifices of the crucible; permitting the melt dropping through the orifices to become spherical droplets in a non-oxidizing gas atmosphere; and rapidly solidifying them.

Abstract: Method and device for producing ball-shaped metallic particles substantially equal in diameter are disclosed. The device comprises a cylindrical metallic housing and a vessel provided on the cylindrical metallic housing. The vessel has a plurality of small openings through a bottom plate thereof. A vibrator is disposed above the vessel in a manner that the vessel may be subjected to vibration. A pair of pipes are provided to deliver and fill nitrogen or inert gas within the housing. An inclined bottom plate having a soft layer is arranged at a bottom portion of the housing to form a shielding structure. An exhaust pipe is provided at an outlet of the inclined bottom plate, and a selector is arranged at a bottom outlet of the shielding structure.

Abstract: In a high-speed fabrication process for producing highly uniform ultra-small metallic micro-spheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. Applied harmonic disturbances are used to control and generate satellite and parent droplets. Significantly, the satellite droplets formed are smaller than the orifice, allowing for the production of smaller metal balls with larger orifices. The satellite droplets are separated from the parent droplets by electrostatic charging and deflection or by aerodynamic or acoustic sorting. Preferably, the satellite droplets are cooled before being collected to avoid defects and achieve high uniformity of the resulting metal balls.

Abstract: The present invention relates to an apparatus and method for the formation of nearly spherical particles, particularly for the formation of metal or metal alloy particles with an induced duplex microstructure. The present invention provides an atomization apparatus having a nozzle positioned at the bottom of a cooling chamber. Rayleigh wave instability may be induced by imparting vibrations to a stream of molten material, which is released under positive pressure upward into a cooling chamber where the stream breaks up into substantially spherical droplets. This produces a plurality of uniform droplets, each droplet having an initial velocity sufficient to follow a unique upward parabolic trajectory above the aperture. These parabolic trajectories carry the individual droplets to a chill body disposed within the cooling chamber, with which they impact while they are at least partially molten.

Abstract: A system and method for making very small (e.g., 1 millimeter diameter) spherical shaped devices is disclosed. The system includes a supply system for providing predetermined amounts of raw material into a chamber, which is used for melting the raw material. The melted raw material is then provided to a dropper for measuring predetermined amounts of the melted raw material (droplets) and releasing the droplets into a drop tube, where they are cooled and solidified into spherical shaped silicon devices. The system includes a container of silicon powder in which the solidified spherical shaped devices are received from the drop tube, the container including a stirring mechanism for agitating the silicon powder. The system also includes a separating device for separating the powder from the solidified spherical shaped devices after the devices have been received into the container.

Abstract: Method and device for producing ball-shaped metallic particles at least almost equal in diameter are disclosed comprising a cylindrical metallic housing, a vessel provided on the cylindrical metallic housing, the vessel having a plurality of small openings through a bottom plate thereof, a vibrator disposed on a mount to locate above the vessel in a manner that the vessel may be subjected to vibration, a pair of pipes provided to locate at an opposition portion of the cylindrical metallic housing to deliver and fill nitrogen or inert gas within the housing, an inclined bottom plate having a soft layer arranged at a bottom portion of the housing to form a shielding structure, an exhaust pipe provided outwardly at an outlet of the inclined bottom plate and a selector arranged at a bottom outlet of the shielding structure.

Abstract: A solder ball having a diameter of 1.2 mm or less, a dispersion of a diameter distribution of 5% or less and sphericity of 0.95 or more, an area ratio of the maximum dendrite being 80% or less of a cross section including a center of the solder ball, comprises a first additional element of 0.5-8 mass% of Ag and/or 0.1-3 mass % of Cu, and 0.006-10 mass %, in total, of at least one second additional element selected from the group consisting of Bi, Ge, Ni, P, Mn, Au, Pd, Pt, S, In and Sb, the balance being substantially Sn. The solder ball is produced by a uniform droplet-spraying method comprising the steps of vibrating a melt of a solder alloy in a crucible under pressure to force the melt to drop through orifices of the crucible; permitting the melt dropping through the orifices to become spherical droplets in a non-oxidizing gas atmosphere; and rapidly solidifying them.

Abstract: In a high-speed fabrication process for producing highly uniform ultra-small metallic micro-spheres, a molten metal is passed through a small orifice, producing a stream of molten metal therefrom. A series of molten metal droplets forms from the break up of the capillary stream. Applied harmonic disturbances are used to control and generate satellite and parent droplets. Significantly, the satellite droplets formed are smaller than the orifice, allowing for the production of smaller metal balls with larger orifices. The satellite droplets are separated from the parent droplets by electrostatic charging and deflection or by aerodynamic or acoustic sorting. Preferably, the satellite droplets are cooled before being collected to avoid defects and achieve high uniformity of the resulting metal balls.

Abstract: Provided is an aerosol method, and accompanying apparatus, for preparing powdered products of a variety of materials involving the use of an ultrasonic aerosol generator (106) including a plurality of ultrasonic transducers (120) underlying and ultrasonically energizing a reservoir of liquid feed(102) which forms droplets of the aerosol. Carrier gas (104) is delivered to different portions of the reservoir by a plurality of gas delivery ports (136) delivering gas from a gas delivery system. The aerosol is pyrolyzed to form particles, which are then cooled and collected. The invention also provides powders made by the method and devices made using the powders.

Abstract: Method for manufacturing solder balls is disclosed. The apparatus comprises a tundish, a vibrator, a cooling liquid tank, an inactive atmospheric chamber, a molten metal receiving tray, a ball collecting barrel and a cooling liquid reservoir. The tundish has orifices at its bottom. The vibrator is immersed in the molten metal of the tundish and generates vibrations. The cooling liquid tank is situated under the tundish and is provided with a cooling liquid heater at its upper and middle outer surface and a cooling liquid cooler at its lower outer surface. The inactive atmospheric chamber is interposed between the bottom of the tundish and the top surface of the cooling liquid. The molten metal receiving tray is seated on a portion of the inactive atmospheric chamber and is horizontally movable. The ball collecting barrel is positioned under the cooling liquid tank and is provided with a cut-off valve at its top, a ball removing valve at its bottom and a cooling liquid supply conduit at its upper portion.

Abstract: The invention relates to a method and device for producing soft solder powder without pressure, in particular for producing spherical fine metal particles having a grain size ranging from 1-100 microns and a liquidus temperature <250 degrees C.

Abstract: A method for manufacturing metal structures in which minute drops of a liquid metal are emitted from an acoustic device through an inert gas. The presence of the inert gas at the surface of the liquid metal prevent the formation of an oxide skin which would absorb acoustic energy and hinder droplet formation and emission. The droplets are then emitted towards a substrate, which may form as a carrier, where they may be used to form solder bumps, circuit traces, or accepted to form a three dimensional device.

Abstract: Improved assembly and methods for manufacturing a three-dimensional object are described. The assembly includes a crucible for holding molten metal, an orifice disposed in the bottom of the crucible through which a jet of molten metal can flow towards a movable substrate, and a mechanically oscillating member immersed in the molten metal for controlling the flow of molten metal through the orifice and for breaking the flow of molten metal into the sequence of molten metal drops. As the drops land on the movable substrate, a three-dimensional object is built up. Continuously variable diameter or controllable planar jets may be used as the orifices. In forming drops from the output of a planar jet, the jet is first broken up by the oscillating member into horizontal cylindrical ligaments and the ligaments are then broken up into drops by acoustic energy applied by audio loudspeakers adjacent the falling ligaments. The assembly and methods are useful in the fields of rapid prototyping and materials processing.

Abstract: A method for manufacturing precise complex three dimensional structures in which minute drops of both a product layer and a sacrificial layer are emitted from an acoustic device. The process is a two step process wherein first the three dimensional structure is built in layers which are composed of either a sacrificial layer or a product layer or some configuration of both. Once the structure has been completely built up, then the sacrificial layer is removed leaving only the complex three dimensional structure.

Abstract: A method for manufacturing metal structures in which minute drops of a liquid metal are emitted from an acoustic device through an inert gas. The presence of the inert gas at the surface of the liquid metal prevent the formation of an oxide skin which would absorb acoustic energy and hinder droplet formation and emission. The droplets are then emitted towards a substrate, which may form as a carrier, where they may be used to form solder bumps, circuit traces, or accreted to form a three dimensional device.

Abstract: Spray atomization of molten metal and/or intermetallic matrix composites reinforced with ceramic particles is practiced by atomizing the matrix into micron sized droplets and depositing the semisolid droplets in a bulk deposition upon a temperature controlled substrate. The semiliquid droplets are injected with refinement particles while in a range of 0 to 40% by volume solid phase and deposited on the substrate surface while in a 40 to 90% by volume solid phase. Refined grain morphology, increased solid solubility, nonequilibrium phases, absence of macro segregation, and elimination of the need to handle fine reactive particles are all achieved by performing the spray deposition process under a controlled atmosphere. Materials fabricated by the process exhibit unusual combinations of properties, such as spatially varying properties.

Abstract: Uniform sized and shaped spheres are formed by applying a minute periodic disturbance to a low viscosity liquid material. Pressure forces the material through at least one orifice in a crucible as a steady laminar stream. The stream enters an enclosed controlled temperature solidification environment which contains at least one heat transfer medium. A charging means is applied to the stream as the stream exits the crucible and breaks into a plurality of spheres to deflect the spheres as they pass through an electric field. The enclosed controlled temperature solidification environment cools and substantially solidifies the spheres.

Abstract: A method and apparatus for the accurate formation of a three-dimensional article comprises providing a supply of substantially uniform size droplets of a desired material wherein each droplet has a positive or negative charge. The supply of droplets is focused or aligned into a narrow stream by passing the droplets through or adjacent an alignment means which repels each droplet toward an axis extending through the alignment means. The droplets are deposited in a predetermined pattern at a predetermined rate onto a target to form the three-dimensional article without the use of a mold of the shape of the three-dimensional article. A means for reducing stress anneals portions of the deposited droplets which form a newly formed surface of the three-dimensional article.

Abstract: Ejection material in powder form used in mechanical plating, each particle of the ejection material being made of an iron alloy core covered with a zinc alloy layer and conducted with thermal treatment at a temperature between 300.degree. and 700.degree. C. so that the zinc alloy layer has the Vicker's hardness of 60 to 370.

Abstract: The present invention is directed to an apparatus for manufacturing a free standing solid metal part. In the present invention metal droplets are produced from a free surface pool of molten metal is when an acoustic wave impacts an acoustic lens that is contiguous with the free standing pool of molten metal. The metal droplets are then charged and deflected toward a target. The build up of the metal droplets combine to form the free standing solid metal part.

Abstract: In order to develop a method for producing at least approximately ball-shaped metallic particles at least almost equal in diameter such that a greater yield of particles at least almost equal in diameter is achieved than in known methods, it is suggested that a continuous stream of liquid metal is acted on locally by compressional vibrations that thereby cross-sectional constrictions are formed in the stream at a distance from each other in longitudinal direction of the stream which lead to the dissection of the stream and that the segments of the dissected stream adopting a ball shape due to the surface tension of the liquid metal are cooled to solidify the liquid metal.

Abstract: A process for producing charged uniformly sized metal droplets in which a quantity of metal is placed in a container and liquified, the container having a plurality of orifices to permit passage of the liquified metal therethrough. The liquified metal is vibrated in the container. The vibrating liquified metal is forced through the orifices, the vibration causing the liquified metal to form uniformly sized metal droplets. A charge is placed on the liquified metal either when it is in the container or after the liquified metal exits the container, the charging thereof causing the droplets to maintain their uniform size. The uniformly sized droplets can be used to coat a substrate with the liquified metal.

Abstract: The present invention relates to a method for granulating a stream of molten metal which falls from a launder or the like, down into a liquid cooling bath contained in a tank. The metal stream divides into droplets in the liquid cooling bath and the droplets solidify and form solid granules. The cooling liquid has substantially uniform flow across the tank in a direction that is substantially perpendicular to the falling metal stream. The flow of cooling liquid has a velocity of less than 0.1 m/sec. The distance from the outlets of the launder to the surface of the liquid cooling bath is kept less than 100 times the diameter of the metal stream measured as the metal stream leaves the launder.

Abstract: Uniform sized and shaped spheres are formed by applying a minute periodic disturbance to a low viscosity liquid material. Pressure forces the material through at least one orifice in a crucible as a steady laminar stream. The stream enters an enclosed controlled temperature solidification environment which contains at least one heat transfer medium. A charging means is applied to the stream as the stream exits the crucible and breaks into a plurality of spheres to deflect the spheres as they pass through an electric field. The enclosed controlled temperature solidification environment cools and substantially solidifies the spheres.