Abstract: A method of increasing the apparent density of agglomerated ligmental titanium or titanium alloy powder produced by the subsurface reduction of titanium tetrachloride vapor or a mixture of titanium tetrachloride and other halide vapors in a flowing stream of alkali or alkaline earth metal or mixtures thereof having a first apparent density after distillation is disclosed. The agglomerated ligmental titanium or titanium alloy powder is introduced into an attriting system wherein the agglomerated ligmental titanium or titanium alloy powder is attrited until the powder becomes more spherical than ligmental and the first apparent density is increased by a factor of from about 3 to about 8. Inert atmosphere may be used to prevent unwanted oxygen contamination.

Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.

Abstract: A system for producing an elemental material or an alloy thereof from a halide of the elemental material or halide mixtures comprising a reactor for introducing the vapor halide of an elemental material or halide mixtures thereof into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in less than or equal to the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal producing particulate elemental material or alloy thereof and particulate halide salt of the reducing metal, a chamber wherein the reaction products are cooled so that substantially all the particulate elemental material or alloy remains unsintered, and a separator for separating the particulate metal or alloy reaction products from the particulate salt.

Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.

Abstract: A method of increasing the apparent density of agglomerated ligmental titanium or titanium alloy powder produced by the subsurface reduction of titanium tetrachloride vapor or a mixture of titanium tetrachloride and other halide vapors in a flowing stream of alkali or alkaline earth metal or mixtures thereof having a first apparent density after distillation is disclosed. The agglomerated ligmental titanium or titanium alloy powder is introduced into an attriting system wherein the agglomerated ligmental titanium or titanium alloy powder is attrited until the powder becomes more spherical than ligmental and the first apparent density is increased by a factor of from about 3 to about 8. Inert atmosphere may be used to prevent unwanted oxygen contamination.

Abstract: A system, method and apparatus for treating a slurry of liquid metal and solid particles is disclosed using various combinations of vacuum distillation and transfer with hot inert gas.

Abstract: A system and method of producing an elemental material or an alloy from a halide of the elemental material or halide mixtures. The vapor halide of an elemental material or halide mixtures are introduced into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in excess of the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal. Particulates of the elemental material or alloy and particulates of the halide salt of the reducing metal are produced along with sufficient heat to vaporize substantially all the excess reducing metal. Thereafter, the vapor of the reducing metal is separated from the particulates of the elemental material or alloy and the particulates of the halide salt of the reducing metal before the particulate reaction products are separated from each other.

Abstract: A method and apparatus for making alloys or ceramics by the subsurface injection of an equilibrium vapor of a boiling liquid of the ceramic or alloys constituents is disclosed. Various powders and products are disclosed.

Abstract: A system for producing an elemental material or an alloy thereof from a halide of the elemental material or halide mixtures comprising a reactor for introducing the vapor halide of an elemental material or halide mixtures thereof into a liquid phase of a reducing metal of an alkali metal or alkaline earth metal or mixtures thereof present in less than or equal to the amount needed to reduce the halide vapor to the elemental material or alloy resulting in an exothermic reaction between the vapor halide and the liquid reducing metal producing particulate elemental material or alloy thereof and particulate halide salt of the reducing metal, a chamber wherein the reaction products are cooled so that substantially all the particulate elemental material or alloy remains unsintered, and a separator for separating the particulate metal or alloy reaction products from the particulate salt.

Abstract: A method of separating metal particulates form a slurry of liquid metal and metal particulates and salt particulates by filtering the slurry to form a cake of metal and salt particulates with some liquid metal. The cake is broken and liquid metal is removed by vacuum distillation or with a hot inert sweep gas at either positon or negative pressure from the broken cake, and thereafter separating the metal and salt particulates. Thereafter, the metal partucilates are sized before water washing to prevent unacceptable explosions upon contact with water.

Abstract: A transfer mechanism between a first vessel containing a slurry of liquid and solids and a second vessel with at least one of said first and second vessels being under a protective atmosphere and/or vacuum. There is a housing in communication with the first and second vessels with a screw having at least one helical thread along the longitudinal shank within the housing for transferring material between vessels. The slurry entering the housing from the first vessel has the solids therein concentrated as the slurry is transported toward the second vessel while liquid is expressed from the slurry until the concentrated solids form a plug isolating the two second vessels as solids discharge into the second vessel.

Abstract: A needle valve is disclosed for controlling the quantity of a halide vapor to be injected into a liquid metal. The needle valve may seat in a supersonic nozzle from which the halide vapor exits. Various products made with the apparatus of the invention are disclosed.