Abstract: A method is disclosed for producing high purity metal powders having an irregular and angular shape and a very low oxygen content (less than 0.25% oxygen in iron and steel powders). The invention utilizes a multiple stage high pressure liquid atomization procedure for converting the molten metal to angular particulate form, and provides for the very rapid subsequent cooling of the hot particle under conditions of high pressure sprays and violent turbulence of the powder particles in the liquid that minimize the formation of oxide impurities on the particles surface. High pressure atomization to produce angular and irregular particles tends to create an oxidizing environment because of the mixture of hot particles and liquid.

Abstract: A method is disclosed for producing high purity metal powders having an irregular and angular shape and a very low oxygen content (less than 0.25% oxygen in iron and steel powders). The invention utilizes a high pressure liquid atomization procedure for converting the molten metal to angular particulate form, and provides for the very rapid subsequent cooling of the hot particles under conditions of high pressure sprays and violent turbulence of the powder particles in the liquid that minimize the formation of oxide impurities on the particle surface. High pressure atomization to produce angular and irregular particles tends to create an oxidizing environment because of the mixture of hot particles and liquid. By rapidly quenching the particles immediately after formation, in a quenching environment that creates a violently turbulent condition at the surface of the metal, the formation of vapor or steam films is minimized and more rapid heat transfer from the particles to the cooling medium is realized.