Abstract: A process for producing powder particles comprises forming an aqueous solution of the metal values of iron, cobalt, nickel and molybdenum, said metals being present in a predetermined ratio, forming from the solution a reducible solid material selected from the group consisting of salts of said metals, oxides of said metals, hydroxides of said metals and mixtures thereof, and reducing said material to form irregular shaped metallic powder particles.

Abstract: A process for forming maraging steel alloys comprise forming an aqueous solution containing the metal values of iron, cobalt, nickel and molybdenum in a predetermined ratio, forming the reducible solid material from the solution, reducing the solid material to form metallic powder particles. These particles are entrained in a carrier gas and fed into a high temperature zone to form droplets. The droplets are cooled to form essentially spherical particles which are agglomerated with a predetermined amount of at least one readily oxidizable metal selected from the group consisting of aluminum, titanium and vanadium. The agglomerates are entrained in a carrier gas and fed into a high temperature zone to form droplets which are thereafter cooled to form essentially spherical shaped particles of a maraging steel alloy containing at least one readily oxidizable metal.

Abstract: A process is disclosed for producing fine spherical powder particles. The process involves forming a relatively uniform admixture of a starting powder material and a flowability aid, the flowability aid being non-reactive with and coarser than the starting material, entraining the admixture in a carrier gas and passing the admixture through a high temperature zone at a temperature above the melting point of the starting material to melt at least about 50% by weight of the starting material, resolidifying the resulting high temperature treated material, and separating the flowability aid from the balance of the high temperature treated material.

Abstract: A process is disclosed for producing spherical glass particles. The process involves forming a high velocity stream of molten droplets of glass, directing said stream toward a repellent surface, impacting the molten droplets against the surface to form fragmented portions, and cooling the fragmented portions to form a glass powder consisting essentially of particles the major portion of which are glass spheres.

Abstract: A process for producing finely divided spherical copper copper alloy powders comprises forming an aqueous solution of copper and alternatively other metal values forming a reducible metallic material from the solution, reducing the material to metal powder particles, subjecting the metal particles to a high temperature zone to melt a portion of the metal powder particles and to form droplets and cooling the droplets to form an essential spherical metal alloy particles.

Abstract: A process for producing spherically shaped maraging steel powder particles containing a readily oxidizable metal comprises forming an aqueous solution containing the metal values of iron, cobalt, nickel and molybdenum, in a predetermined ratio, forming a reducible solid material from the solution reducing the solid material to form metallic poweder particles. These particles are agglomerated with a predetermined amount of a second group consisting of at least one readily oxidizable metal selected from the group consisting of aluminum, titanium and vanadium. The agglomerates are entrained in a carrier gas and fed into a high temperature zone and droplets are formed. The droplets are cooled to form essentially spherical shaped particles of a maraging steel alloy containing at least one readily oxidizable metal.

Abstract: A disc is disclosed which comprises a top layer, a middle layer, and a bottom layer. The top layer is placed proximate to a high temperature reactor and at least the outer surface of the top layer is made of a material which allows it to act as a substrate against which molten particles are impacted to microatomize the particles. The layers are positioned one above the other with a first space between the bottom surface of the top layer and the top surface of the middle layer, and a second space between the bottom surface of the middle layer and the top surface of the bottom layer. The top and bottom layers are joined together and stabilized by a peripheral wall around the circumferential edge of the top and bottom layer. The middle layer is fixedly mounted to the bottom layer. The middle layer is smaller in diameter than the diameters of the top and bottom layers so that a third space is defined between the inner surface of the peripheral wall and the circumferential edge of the middle layer.

Abstract: A process is disclosed for producing discontinuous metal foils. The process involves entraining metal powder particles in a carrier gas and passing the powder particles through a high temperature zone at a temperature above the melting point of the powder particles to melt at least about 50% by weight of the powder particles and thereafter resolidifying the resulting high temperature treated material by impacting the material against a substrate to form the foils.

Abstract: A process is disclosed for producing metal flakes. The process involves entraining the metal powder particles in a carrier gas and passing the powder particles through a high temperature zone at a temperature above the melting point of the powder particles to melt at least about 50% of the powder particles, resolidifying the resulting high temperature treated material by impacting the material against a substrate, and thereafter contacting the material with a non-oxidizing gas which can be nitrogen, argon, hydrogen, helium or combinations of these to remove the material from the substrate in the form of flakes.

Abstract: A process for producing finely divided spherical refractory metal based powders comprises forming an aqueous solution containing at least one refractory metal, forming a solid reducible refractory metal based material containing a compound selected from the group consisting of refractory metal salts, refractory metal oxides, hydroxides and mixtures thereof, reducing the solid material to refractory metal based powder particles, subjecting the refractory based metal particles to a high temperature zone to melt a portion of the particles and cooling the molten material to form essentially spherical refractory metal based powder particles.

Abstract: A process for producing finely divided spherical precious metal based powders comprises forming an aqueous solution containing a source of at least one precious metal value forming a solid reducible precious metal material from the solution, reducing the solid material to precious metal powder particles, subjecting the precious metal based particles to a high temperature zone to melt at least a portion of the precious metal based powder particles and cooling the molten material to form essentially spherical precious metal based alloy particles.

Abstract: A process for producing finely divided spherical metal low melting temperatures powders comprises forming an aqueous solution metals, forming a reducible solid material from the solution, reducing the solid to metal powder particles, subjecting the metal particles to a high temperature zone to melt a portion of the metal powder particles and to form droplets and cooling the droplets to form essentially spherical metal particles.

Abstract: A process is disclosed for producing finely divided spherical glass powders. The process comprises forming a coating of a surface active agent which can be of the nonionic or anionic type on the surfaces of the particles of a glass powder, feeding the coated particles and a carrier gas into a high temperature zone and maintaining the particles in the zone for a sufficient time to melt at least about 50% by weight of the particles and to form droplets therefrom, and cooling the droplets to form glass particles having essentially a spherical shape with the majority of the particles having an average particle size of less than about 25 micrometers in diameter which is essentially the same size as the starting glass particles.

Abstract: A process is disclosed for producing finely divided spherical metal powders. The process comprises forming a coating of a surface active agent which can be of the nonionic or anionic type on the surfaces of the particles of a metal powder, feeding the coated particles and a carrier gas into a high temperature zone and maintaining the particles in the zone for a sufficient time to melt at least about 50% by weight of the particles and to form droplets therefrom, and cooling the droplets to form metal particles having essentially a spherical shape with the majority of the particles having a size less than about 50 micrometers.