Abstract: The embodiments disclosed herein are directed to systems, methods, and devices for processing a material using a microwave plasma apparatus with an interior liner. In some embodiments, the liner comprises a reduction resistant material layer in direct contact with a hydrogen-containing plasma of a plasma processing apparatus. In some embodiments, the liner may comprise a sleeve disposed between a plasma and one or more concentric tubes of a plasma processing apparatus. In some embodiments, the liner may comprise a coating of material applied to the one or more concentric tubes. In some embodiments, the liner may comprise a flexible ceramic material, such as a ceramic ribbon that is coiled or wrapped in a helix shape spiraling around the interior of the one or more concentric tubes.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. By utilizing a microwave plasma, control over spheriodization and resulting microstructure can be tailored to meet desired demands.

Abstract: The embodiments disclosed herein are directed to systems, methods, and devices for pyrolysis of methane in a microwave plasma for hydrogen production and structured carbon powder. Some methods are directed to producing a structured carbon powder using a microwave generated plasma comprising injecting a plasma gas comprising methane (CH4) into a liner, the liner in communication with a microwave waveguide; propagating microwaves through the microwave waveguide, the microwaves generated using a microwave generator; and generating a microwave plasma by contacting the plasma gas with the microwaves.

Abstract: Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.

Abstract: Disclosed herein are devices, systems and methods of use of an improved liner for a plasma torch. In particular, a segmented liner for use in a plasma torch (e.g., annular torch, swirl torch) is provided. In general, the improved segmented liner has improved thermal shock resistance capabilities over conventional unitary liners.

Abstract: A method of real time optimization of a microwave plasma includes adjusting in real time an injection angle of a swirl gas flow of the microwave plasma, the magnitude of the swirl gas flow of the microwave plasma, or the microwave power applied to the microwave plasma.

Abstract: Disclosed herein are systems, methods, and devices processing feed material utilizing a microwave plasma apparatus comprising a powder ingress preventor (PIP). In some embodiments, the microwave plasma apparatus comprises a core plasma tube and a liner; and a ring structure comprising: a bearing surface, the bearing surface contacting an interior diameter of the core plasma tube; and an opening, the opening contacting an outer diameter of the liner.

Abstract: Described herein are embodiments directed to additive manufacturing (AM), including three-dimensional (3D) printing, of metal nitride ceramics. In some embodiments herein, AM may comprise powder bed fusion (PBF) techniques. Also described herein are metal nitride ceramic components formed by AM techniques and methods for forming metal nitrides capable of being used in AM processes.

Abstract: Disclosed herein are systems, methods, and devices processing feed material utilizing an upstream swirl module and composite gas flows. Some embodiments are directed to a microwave plasma apparatus for processing a material, comprising: a first flow module, a second flow module, and a liner.

Abstract: Some embodiments herein are directed to devices and methods for automatically starting a plasma utilizing a wand. In some embodiments, the wand may be used to start a plasma in a plasma torch such as, for example, a microwave plasma torch or an induction plasma torch, as discussed below. The wand may comprise an elongate, hollow wand member comprising a closed distal end, a proximal end, and one or more apertures extending from a hollow interior of the wand member to an exterior surface of the wand member; and an elongate wire member positioned within the hollow interior of the wand member and extending along at least a portion of a length of the wand member, wherein the wire member is configured to be placed in operable communication through the aperture with a power source, such that the power source can be activated to in turn start the plasma within the plasma torch.

Abstract: Methods are disclosed for producing product particles having a uniform size using a microwave plasma process. More particularly, methods of the present technology are used to manufacture product particles having a core at least partially surrounded by a shell. The core and shell of the product particles are chemically distinct. Methods of the present technology occur within a plasma chamber of a microwave plasma reactor and a microwave formed plasma is utilized to vaporize core precursor material.

Abstract: Disclosed herein are embodiments of systems and method for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertain to metal powders. Microwave plasma processing can be used to spheroidize the metal powders and form metal nitride or metal carbide powders. The stoichiometry of the metal nitride or metal carbide powders can be controlled by changing the composition of the plasma gas and the residence time of the feedstock materials during plasma processing.

Abstract: Disclosed herein are embodiments of strain tolerant particles, methods of manufacturing such structures, and feedstock to form said structures. In some embodiments, the structures can include alternating regions of an energy storage structure and a reinforcing structure. Advantageously, when the strain tolerant particles are used within an anode of a lithium ion battery, the reinforcing structure may provide mechanical stability to the particles and thus increase cycle life.

Abstract: Methodologies, systems, and devices are provided for producing metal spheroidal powder products. Dehydrogenated and spheroidized particles are prepared using a process including introducing a metal hydride feed material into a plasma torch. The metal hydride feed material is melted within a plasma in order to dehydrogenate and spheroidize the materials, forming dehydrogenated and spheroidized particles. The dehydrogenated and spheroidized particles are then exposed to an inert gas and cooled in order to solidify the particles into dehydrogenated and spheroidized particles. The particles are cooled within a chamber having an inert gas.

Abstract: An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.

Abstract: Methods are disclosed for producing core-shell particles having a uniform size using a microwave plasma process. More particularly, methods of the present technology are used to manufacture core-shell particles having a core at least partially surrounded by a shell. The core and shell of the core-shell particles are chemically distinct. Methods of the present technology occur within a plasma chamber of a microwave plasma reactor and a microwave formed plasma is utilized to vaporize core precursor material.

Abstract: An apparatus for providing material feedstock into a plasma of a plasma torch includes a material feeding device having an input end and an output end. The output end of the material feeding device extends at least partially around the periphery of a plasma generated near the output end of the plasma torch. The material feeding device is oriented at an angle with respect to a central axis of the plasma torch.

Abstract: Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to unique powder feedstocks such as Tantalum, Yttrium Stabilized Zirconia, Aluminum, water atomized alloys, Rhenium, Tungsten, and Molybdenum. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

Abstract: Disclosed herein are embodiments of mechanically alloyed powder feedstock and methods for spheroidizing them using microwave plasma processing. The spheroidized powder can be used in metal injection molding processes, hot isostatic processing, and additive manufacturing. In some embodiments, mechanical milling, such as ball milling, can be used to prepare high entropy alloys for microwave plasma processing.

Abstract: Disclosed herein are embodiments of doped and undoped spherical or spheroidal lithium lanthanum zirconium oxide (LLZO) powder products, and methods of production using microwave plasma processing, which can be incorporated into solid state lithium ion batteries. Advantageously, embodiments of the disclosed LLZO powder display a high quality, high purity stoichiometry, small particle size, narrow size distribution, spherical morphology, and customizable crystalline structure.