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: An atomizing apparatus for the production of powders or spray deposits, having an atomization device for receiving a liquid stream of molten metal or metal alloy to be atomized; at least two primary atomization gas jets for directing an atomization gas at an angle into the liquid stream in an atomization zone at an impinging point of the atomization jets to break the stream into atomized droplets; and at least two secondary jets for direction a controlling fluid at a pressure, flow rate and direction, the jets being aimed at the atomization gas jet or into the atomization zone, wherein said secondary jets control a backpressure generated by the primary atomization gas jets. The apparatus also includes means for in-situ controlling at least one of the relative positions among the primary atomization jets, the secondary jets, and the liquid delivery nozzle.

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: A method of producing an FeCrAl material by gas atomization, and a high temperature material produced by the method. In addition to containing iron (Fe), chromium (Cr), and aluminium (Al) the material also contains minor fractions of one or more of the materials molybdenum (Mo), hafnium (Hf), zirconium (Zr), yttrium (Y), nitrogen (N), carbon (C) and oxygen (O). The smelt to be atomized contains 0.05-0.50 percent by weight tantalum (Ta) and less than 0.10 percent by weight titanium (Ti). Nitrogen gas (N2) is used as an atomizing gas, to which an amount of oxygen gas (O2) is added, the amount of oxygen gas being such as to cause the atomized powder to contain 0.02-0.10 percent by weight oxygen (O) and 0.01-0.06 percent by weight nitrogen (N).

Abstract: A fine powder of metallic copper, suitable as a material for electroconductive pastes, and having a BET diameter of 3 &mgr;m or less, large crystallite size, high dispersibility and particles of high sphericity and a process for producing the same. More specifically, a fine powder of metallic copper having a BET diameter of 3 &mgr;m or less, particles of high sphericity and crystallites of 0.1 to 10 &mgr;m in size, and more preferably containing oxygen at 0.3% by weight or less. Moreover, the fine powder of metallic copper can be produced stably and efficiently by blowing an ammonia-containing gas onto molten copper kept at 1120° C. More specifically, it can be produced more stably and efficiently by blowing ammonia at 0.015 L/minute or more per unit area (cm2) of the molten copper.

Abstract: A relatively high carbon, water-atomized, steel shot is softened via annealing to render it suitable for ballistic use. The annealing preferably includes decarburization from a surface layer or throughout and preferably provides the shot with a surface Knoop hardness of less than 250.

Abstract: A process of producing a zinc or zinc alloy powder (4) for batteries which comprises dropping molten zinc or a molten zinc alloy to form a molten metal droplets stream (1) and striking an atomizing medium jet (3) emitted from a nozzle (2) against the molten metal stream (1) at right angles to atomize the molten zinc or the molten zinc alloy, wherein two or more the nozzles are arranged in parallel to each other, the orifice of each of the nozzles has a V-shaped, U-shaped, X-shaped or arc-shaped cross-section, the atomizing medium is air or an inert gas, two or more the molten metal streams have at least two different flow rates selected from a range 0.04 to 0.25 kg/sec, and two or more the atomizing medium jets have at least two different atomizing pressures selected from a range 4 to 9 kg/cm2.

Abstract: Improved hydrogen storage materials are disclosed. A first material comprises a hydrogen storage nanomaterial that contains nanoparticles or nanoparticle clusters of a metal that is capable of combining with hydrogen to form a metal hydride. The nanomaterials may be formed using a thermal spray process. A second material comprises a micro-sized support that contains a hydrogen storage material deposited thereon. The hydrogen storage material may comprise a thermal spray deposit formed on a fly ash particle. A third material comprises a hydrogen permeable container having a hydrogen storage material therein. The container may comprise a microparticle having an internal void (e.g., a fly ash cenosphere or glass microsphere) containing a hydrogen storage material that has been permeated therein. Alternatively, the container may comprise an enclosing layer formed over a hydrogen storage material.

Abstract: A process of producing a zinc or zinc alloy powder (4) for batteries which comprises dropping molten zinc or a molten zinc alloy to form a molten metal droplets stream (1) and striking an atomizing medium jet (3) emitted from a nozzle (2) against the molten metal stream (1) at right angles to atomize the molten zinc or the molten zinc alloy, wherein two or more the nozzles are arranged in parallel to each other, the orifice of each of the nozzles has a V-shaped, U-shaped, X-shaped or arc-shaped cross-section, the atomizing medium is air or an inert gas, two or more the molten metal streams have at least two different flow rates selected from a range 0.04 to 0.25 kg/sec, and two or more the atomizing medium jets have at least two different atomizing pressures selected from a range 4 to 9 kg/cm2.

Abstract: Provided are palladium-containing powders and a method and apparatus for manufacturing the palladium-containing particles of high quality, of a small size and narrow size distribution. An aerosol is generated from liquid feed and sent to a furnace, where liquid in droplets in the aerosol is vaporized to permit formation of the desired particles, which are then collected in a particle collector. The aerosol generation involves preparation of a high quality aerosol, with a narrow droplet size distribution, with close control over droplet size and with a high droplet loading suitable for commercial applications. Powders may have high resistance to oxidation of palladium. Multi-phase particles are provided including a palladium-containing metallic phase and a second phase that is dielectric. Electronic components are provided manufacturable using the powders.

Abstract: A metal powder produced by a process which comprises directing at least three successive gas beams at a molten metal stream inside an atomization chamber, the at least three gas beams being oriented in different directions. This abstract is neither intended to define the invention disclosed in this specification nor intended to limit the scope of the invention in any way.

Abstract: A discontinuously reinforced metal composite, having a metal matrix and a plurality of intermetallic particles comprising at least two different metals, the intermetallic particles having a size ranging from 1 &mgr;m to about 10 &mgr;m and being dispersed within the metal matrix in an amount of at least 20% by volume, wherein the intermetallic particles are particles having at least one same metal as the metal in the metal matrix.

Abstract: A mist of liquid coolant is introduced into the path of atomized, molten, solder droplets. The mist and other conditions within the chamber are engineered to enable the liquid coolant droplets in the mist to contact the surfaces of molten solder droplets and be flash vaporized upon contact, thereby rapidly extracting heat from the molten solder droplets and accelerating cooling and solidification to produce an enhanced solder ball as a product of this process.

Abstract: This invention relates to the synthesis of a new generation of metastable aluminum-titanium (Al—Ti) alloys and the process of making them. The preparation method used is a combination process incorporating the advantages of conventional casting and spray techniques. The process is a low cost process. The aluminum-titanium materials made in this invention contain titanium in both the reacted and unreacted form. The results were confirmed using microstructural and x-ray diffraction studies. The presence of phases clearly indicate the metastable nature of these materials in accordance with the equilibrium phase diagram established for Al—Ti system. The Al—Ti materials can be made in the dimensions suitable for structural applications at ambient and elevated temperatures and as control materials for synthesis of more dilute equilibrium Al—Ti materials using conventional techniques such as casting.

Abstract: A tablet formed by prealloys iron-aluminum produced from automized powders to be used as additive element in aluminum alloys, is manufactured by the method having the steps of obtaining a metallic alloy by fusion of iron and aluminum with the iron and aluminum added in an electric arc or induction furnace, automizing the melted alloy by transporting the melted alloy to an intermediary contsiner with an opening as a metal flux controlled by a valve located in the opening for controlling and proportionating a continuous flux and supplying a jet of water under pressure when the liquid metal drains to provide a atomization and to produce small droplets that cool in water, solidify and are deposited as a powder; reducing humidity of the powder; classifying the thusly produced material, and compacting a thin fraction of the material for obtaining tablets; a tablet.

Abstract: A method of producing an FeCrAl material by gas atomization, wherein in addition to containing iron (Fe), chromium (Cr) and aluminium (Al) the material also contains minor fractions of one or more of the materials molybdenum (Mo), hafnium (Hf), zirconium (Zr), yttrium (Y), nitrogen (N), carbon (C) and oxygen (O). The invention is characterized by causing the smelt to be atomized to contain 0.05-0.50 percent by weight tantalum (Ta) and, at the same time, less than 0.10 percent by weight titanium (Ti). According to one highly preferred embodiment, nitrogen gas (N2) is used as an atomizing gas to which a given amount of oxygen gas (O2) is added, said amount of oxygen gas being such as to cause the atomized powder to contain 0.02-0.10 percent by weight oxygen (O) at the same time as the nitrogen content of the powder is 0.01-0.06 percent by weight. The invention also relates to a high temperature material.

Abstract: A silicon base binary alloy of prealloyed powder having less than 10% aluminum, excluding zero. The alloy may be in the form of gas atomized prealloyed powder, which powder may be consolidated to form an article. Preferably, the article is a sputtering target.

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: In a method for atomizing metal melts, in which the liquid metal bath is sprayed from a tundish via an outlet opening by the aid of a gas into a cooling chamber, or onto a surface to be coated while compacting the comminuted particles by the aid of a propellant gas, the liquid metal melt via an annular gap is introduced into the outlet opening, into which a hot gas having a temperature of between 250° C. and 1300° C. and a supercritical pressure of between 2 and 30 bars is ejected through a Laval nozzle concentrically with said opening. The hot gas is contacted with the melt bath at a speed exceeding supersonic speed, with a radial outwardly directed component or with a twist.

Abstract: A two-stage method for producing ultra-fine and environmentally stable solid powders from a metal composition including a reactive alloying element. The method includes the steps of: (a) operating a first-stage heating and atomizing means to provide a stream of super-heated fine-sized metal liquid droplets into a chamber of a second-stage atomizing means with the second-stage atomizing means containing a supply of an atomizing fluid medium composed of at least a reactive gas and an inert gas at a predetermined proportion; (b) operating the second-stage atomizing means by directing the atomizing fluid medium into the chamber to impinge upon the stream of super-heated metal liquid droplets to further break up the metal liquid droplets into ultra-fine particles and to allow the reactive gas to react with the reactive alloying element for forming a protective layer on the exterior surface of the particles; and (c) cooling the particles to form ultra-fine solid powders.

Abstract: Magnetic alloy powder for a permanent magnet contains: R of about 20 mass percent to about 40 mass percent (R is Y, or at least one type of rare earth element); T of about 60 mass percent to about 79 mass percent (T is a transition metal including Fe as a primary component); and Q of about 0.5 mass percent to about 2.0 mass percent (Q is an element including B (boron) and C (carbon)). The magnetic alloy powder is formed by an atomize method, and the shape of particles of the powder is substantially spherical. The magnetic alloy powder includes a compound phase having Nd2Fe14B tetragonal structure as a primary composition phase. A ratio of a content of C to a total content of B and C is about 0.05 to about 0.90.

Abstract: The device for atomizing and comminuting liquid melts, including a slag tundish to whose outlet an expansion or cooling chamber is connected, whereby a propellant gas lance opens into the outlet, which propellant gas lance is surrounded by a tubular underflow weir immersed in the liquid slag, is dimensioned such that the width of the gap between the lower edge of the underflow weir and the tundish bottom is smaller than 20%, preferably smaller than 15%, of the clear width of the outlet, that the bottom of the tundish in the region between the lower edge of the overflow weir and the outlet is designed in a funnel-shaped manner, and that supercritical vapor is injected through the propellant gas lance to form an underexpanded free jet in the interior of the melt jet, the flow speed at the nozzle mouth of the lance being adjusted to sonic speed, thus ensuring a substantially enhanced comminution performance.

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: Disclosed is a method for the preparation of a sintered body of a high-chromium cast iron of a specified chemical composition having greatly improved mechanical, abrasion-resistant and corrosion-resistant properties as compared with conventional cast bodies of the same cast iron. The inventive method comprises the steps of preparing a powder of the cast iron alloy by quenching solidification of a melt, e.g., by centrifugal spray atomization, and sintering the powder under compression by the discharge plasma sintering method.

Abstract: An iron-graphite composite powder having a microstructure comprising carbon clusters embedded in a ferrous matrix is disclosed. Also disclosed is a process for preparing the iron-graphite composite powder, a process for preparing sintered articles from this composite powder and the sintered articles prepared thereby.

Abstract: The invention concerns a low pressure for the preparation of an iron-based, optionally alloyed powder comprising the steps of preparing a raw powder essentially consisting of iron and optionally at least one alloying element selected from the group consisting of chromium, manganese, copper, nickel, vanadium, niobium, boron, silicon, molybdenum and tungsten; charging a gas tight furnace with the powder in an essentially inert gas atmosphere and closing the furnace; increasing the furnace temperature; monitoring the increase of the formation of CO gas and evacuating gas from the furnace when a significant increase of the CO formation is observed and cooling the powder when the increase of the formation of CO gas diminishes.

Abstract: A relatively high carbon, water-atomized, steel shot is softened via annealing to render it suitable for ballistic use. The annealing preferably includes decarburization from a surface layer or throughout and preferably provides the shot with a surface Knoop hardness of less than 250.

Abstract: The present invention concerns additives for non-ferrous, liquid metals. The additives consist of compacted bodies of essentially pure iron particles.

Abstract: Process and a device for producing metal powders from molten metal. The process includes the provision of molten metal in a metallurgical vessel having a nozzle element, the nozzle element being directed into an atomization chamber associated with the metallurgical vessel. The molten metal is allowed to flow through the nozzle element of the metallurgical vessel into the atomization chamber whereby a molten metal stream is fed into the atomization chamber. At least three successive gas beams are directed at the molten metal stream inside the atomization chamber, the at least three gas beams being oriented in different directions. Thereby the molten metal stream is broken down into droplets which subsequently freeze into grains that are collected.

Abstract: An aluminum-based alloy having the general formula Al100−(a+b)QaMb (wherein Q is V, Mo, Fe, W, Nb, and/or Pd; M is Mn, Fe, Co, Ni, and/or Cu; and a and b, representing a composition ratio in atomic percentages, satisfy the relationships 1≦a≦8, 0<b<5, and 3≦a+b≦8) having a metallographic structure comprising a quasi-crystalline phase, wherein the difference in the atomic radii between Q and M exceeds 0.01 Å, and said alloy does not contain rare earths, possesses high strength and high rigidity. The aluminum-based alloy is useful as a structural material for aircraft, vehicles and ships, and for engine parts; as material for sashes, roofing materials, and exterior materials for use in construction; or as materials for use in marine equipment, nuclear reactors, and the like.

Abstract: A rare earth permanent magnet alloy having a composition expressed as RxF100−(x+y+z+m+n)ByTzMmDn. In this formula, R is one or more of rare earthy elements, such as neodymium, lanthanum, cerium, dysprosium and/or praseodymium; F is Fe or Fe and up to 20 atomic percent of Co by substitution; B is boron; T is one or more elements selected from the group of Ti, Zr, Cr, Mn, Hf, Nb, V, Mo, W and Ta; M is one or more elements selected from the group of Si, Al, Ge, Ga, Cu, Ag, and Au; and D is one or more elements selected from the group of C, N, P, and O. In this formula, x, y, z, m, n are atomic percentages in the ranges of 3<x<15, 4<y<22, 0.5<z<5, 0.1<m<2, and 0.1<n<4. Fine amorphous particles of such alloy are made by atomization and/or splat-quenching. Both substantially-spherical, irregular and substantially plate-like particles are simultaneously produced.

Abstract: Provided are silver-containing powders and a method and apparatus for manufacturing the silver-containing particles of high quality, of a small size and narrow size distribution. An aerosol is generated from liquid feed and sent to a furnace, where liquid in droplets in the aerosol is vaporized to permit formation of the desired particles, which are then collected in a particle collector. The aerosol generation involves preparation of a high quality aerosol, with a narrow droplet size distribution, with close control over droplet size and with a high droplet loading suitable for commercial applications.

Abstract: An atomizing method for producing metal powder, including splitting molten metal in the vicinity of an exit of a nozzle by introducing the molten metal into a center of the nozzle, wherein gas is flowing through the nozzle. The split molten metal is then further split into fine particles by liquid ejected in an inverse cone shaped flow from a slit surrounding a lower side of the nozzle. The resulting powder is of fine size and spherical or granular shape, and is suitable for metal injection shaping.

Abstract: The sputtering target is manufactured by adjusting the ratio of the gas flow volume (Nm3)/molten liquid flow mass (kg) to 5 Nm3/kg or more in the gas atomizing step of the spray forming method using an Al or Al alloy sputtering target material in which the maximum length of all the inclusions is 20 &mgr;m or less.

Abstract: A method for efficiently producing particles from gas phase chemical reactions induced by a radiation beam. The apparatus includes a reaction chamber and an elongated reactant inlet, where the reaction chamber is configured to conform generally to the elongated shape of the reactant inlet. Shielding gas may be introduced to form a blanket of inert gas on both sides of the reactant stream. A feed back loop may be used to maintain the desired pressure within the reaction chamber.

Abstract: The present invention concerns additives for non-ferrous, liquid metals. The additives consist of compacted bodies of essentially pure iron particles.

Abstract: This invention relates to a spray coating powder material which, when applied to gas turbines using a crude low-quality fuel oil as fuel, has sufficiently higher corrosion resistance to sulfur, vanadium, sodium and other substances that accelerate corrosion in a high-temperature service environment, than conventional materials such as Ni-50 Cr and MCrAlY materials, as well as high-temperature components coated therewith. Specifically, this invention relates to a spray coating powder material comprising, on a weight percentage basis, greater than 45% and up to 60% of chromium, 5 to 15% of aluminum, 0.5 to 10% of zirconium, and the balance comprising cobalt or iron, or both, and incidental impurities, as well as high-temperature components coated therewith. This material can yield a sprayed coating having high corrosion resistance to sulfur, vanadium, sodium and other substances that accelerate corrosion in a high-temperature service environment.

Abstract: A method and spray forming system for effectively spraying the inner diameters of intricate objects and makes inner diameter spray forming practical for articles that have various and complicated inner geometries. The spray forming system can include at least one of a rotating mandrel and preform, and atomizer, which is fed with liquid metal, to form a spray. The atomizer is positioned with respect to inner walls of at least one of the rotating mandrel and preform to accurately and fully spray form an inner diameter of an article, even if the article has complicated and irregular inner surfaces.

Abstract: A method of making hydrogen storage powder resistant to fracture in service involves forming a melt having the appropriate composition for the hydrogen storage material, such, for example, LaNi.sub.5 and other AB.sub.5 type materials and AB.sub.5+x materials, where x is from about -2.5 to about +2.5, including x=0, and the melt is gas atomized under conditions of melt temperature and atomizing gas pressure to form generally spherical powder particles. The hydrogen storage powder exhibits improved chemcial homogeneity as a result of rapid solidfication from the melt and small particle size that is more resistant to microcracking during hydrogen absorption/desorption cycling. A hydrogen storage component, such as an electrode for a battery or electrochemical fuel cell, made from the gas atomized hydrogen storage material is resistant to hydrogen degradation upon hydrogen absorption/desorption that occurs for example, during charging/discharging of a battery.

Abstract: A method of producing coated powder material is provided. In the method, molten metal or metal alloy is caused to fall in a stream (3) and is then atomized into a spray. A liquid or solid material of different composition is introduced and caused to contact the stream or spray so that a coating is formed over all or part of the surface of the atomized droplets. The coating may be the introduced material or a reaction product.

Abstract: A method of producing semi-finished metal iron or nickel-based products by spray forming in which one or more jets of nitrogen or a nitrogen-containing gas are directed onto a stream of molten alloy to atomise the same. A titanium addition is made to the liquid alloy before spray forming occurs. The atomised liquid or partially solidified droplets of alloy collect on a substrate to produce a semi-finished product.

Abstract: The invention encompasses methods of utilizing atomization, methods for forming magnet powders, methods for forming magnets, and methods for forming bonded magnets. The invention further encompasses methods for simulating atomization conditions. In one aspect, the invention includes an atomization method for forming a magnet powder comprising: a) forming a melt comprising R.sub.2.1 Q.sub.13.9 B.sub.

Abstract: This invention relates to a method and apparatus for atomizing a liquid stream of metal or metal alloy. This invention relates to producing powders as well as to spray deposition process. During atomizing, a backpressure is created below the exit of the liquid delivery nozzle by the impingement of the atomization gas jets around the atomization zone. And this may block further atomization. The present invention provides a method of atomizing and an atomizing apparatus to control the backpressure. During atomizing, the intensities and directions of the atomization gas jets affects the atomization characteristics. The present invention provides a method of atomizing and an atomizing apparatus to control both the intensities and directions of the atomization gas jets.

Abstract: A process for producing an oxide dispersion strengthened heat resisting powder metallurgy alloy, characterized in that (1) zirconium and/or a rare earth element, such as yttrium, cerium, or lanthanum, are previously added as an oxide former element to a molten mother alloy, (2) an atomizing gas composed of an argon or nitrogen gas containing not more than 5.0% by volume of oxygen is used in the step of gas-atomizing the molten mother alloy, and (3) in the step of consolidating and molding the gas-atomized alloy powder by rolling, forging, HIP, or hot extrusion, the alloy powder is sieved to a particle diameter of not more than 110 .mu.m before this step. The oxide dispersion strengthened heat resisting powder metallurgy alloy is characterized in that (1) zirconium and/or a rare earth element, such as yttrium, cerium, or lanthanum, are contained in an amount of 0.05 to 3.0% by weight and (2) the powder metallurgy consolidated, molded product prepared by consolidation of the powdery metallurgy alloy contains 0.

Abstract: A method of making a metal slab with a non-uniform cross-sectional shape including providing a spray casting apparatus including a substrate and a plurality of spaced atomization nozzles, the nozzles having a discharge opening and introducing molten metal into the nozzles. The method then includes atomizing the molten metal as it is discharged from the nozzles through the discharge openings by subjecting the discharged molten metal to jets of an atomizing gas in order to form metal droplets for deposition onto the substrate. The deposition of the metal droplets onto the substrate is controlled in order to form the metal slab having a non-uniform cross-sectional shape. A method of making an integrally stiffened metal structure as well as metal and aluminum products made by the above methods are also provided.

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: A method for stably producing metal beryllium pebbles each ranging from 0.1 to 1.8 mm in particle diameter and 0.05 to 0.6 mm in crystal grain average diameter. The metal beryllium pebbles obtained by the invention are excellent not only in tritium emission power but also in anti-swelling property, and are thus useful as a material for nuclear fusion reactors. The metal beryllium pebbles can also be advantageously employed for aerospace structural materials and the like, by utilizing their light weight and high melting point properties.

Abstract: Repetitively pulsed plasma jets generated by a capillary arc discharge at high stagnation pressure (>15,000 psi) and high temperature (>10,000 K) are utilized to produce 0.1-10 .mu.m sized metal powders and decrease cost of production. The plasma jets impact and atomize melt materials to form the fine powders. The melt can originate from a conventional melt stream or from a pulsed arc between two electrodes. Gas streams used in conventional gas atomization are replaced with much higher momentum flux plasma jets. Delivering strong incident shocks aids in primary disintegration of the molten material. A series of short duration, high pressure plasma pulses fragment the molten material. The pulses introduce sharp velocity gradients in the molten material which disintegrates into fine particles. The plasma pulses have peak pressures of approximately one kilobar. The high pressures improve the efficiency of disintegration. High gas flow velocities and pressures are achieved without reduction in gas density.

Abstract: An economical process and associated hardware for commercial manufacture of controllable submicrometer size metallic powders for electronic and other applications. The method is based on the preparation of a stable high concentration precursor solution, production of a high density aerosol mist of the precursor solutions, selection of mist droplets with upper and lower size bounds, controlled drying of the droplets, their conversion to metallic powder in a high temperature gaseous atmosphere and the separation of the powders from carrier gases without significant loss inside the process hardware.

Abstract: A process for producing spherical metal particles comprises the step of spraying a molten metal in a chamber filled with a refrigerant gas through a centrifugal atomizer, wherein the refrigerant gas is a composition comprising nitrogen and oxygen gases or nitrogen gas and air and the concentration of the oxygen ranges from 3 to 600 ppm on the basis of the weight of the composition. The production process of the present invention permits mass-production of fluent, spherical metal particles having a smooth surface, in low cost and excellent in dispersibility in a dispersing medium, which is required when the particles are used as a component for pastes or paint and varnishes, while using a small-sized chamber.