Abstract: A process is disclosed for producing plasma type spray powders. The process involves forming, an admixture of a base metal, chromium, aluminum, and yttrium or master alloy powders containing these elements, and dry milling the admixture by high shearing to produce a homogeneous mixture. A slurry of this mixture and an aqueous solution of a binder is then spray dried to produce agglomerates, the major portion of which has a particle size of from about 20 to about 53 microns. This major portion is then separated from the remainder of the agglomerates and sintered in a reducing atmosphere to remove the binder and form a sintered powder. The sintered powder is then passed through a high temperature plasma reactor to melt the powder and produce a homogeneous plasma spray powder.

Abstract: Atomizing techniques produce fine and uniform ceramic powders and metal powders, by melting the particulate metal or ceramic to be atomized at high temperatures in a plasma melting torch, impacting the stream of high temperature gas and drops of molten feed material against a suitable moving impact substrate to produce fine droplets, and chilling these droplets in a quench gas to produce rapid solidification, optimizing internal crystal structure. The substrate is formed as a disk or belt moved continuously to produce constantly changing impact zones, and a liquid rinsing and squeegee wiping operation or a vacuum cleaning operation is employed to clear the substrate of any accumulated residue of the impacted material. The rapidly solidified particles are recovered by filtration or separating steps from the quench gas and the rinsing liquid. A preferred impact substrate material is a thin layer or Teflon FEP laminated to a slightly thicker layer of aluminum foil.

Abstract: A fine aluminum metallurgical powder suitable for compacting and sintering into densified articles which includes a dispersed phase is produced by directing a stream of molten droplets at a repellent surface to produce smooth surfaced and melt solidified particles having an average particle size of less than about ten micrometers.

Abstract: A fine amorphous metallurgical powder suitable for compacting and sintering into amorphous densified articles which consist essentially of a major portion by weight a transition metal or combination thereof and less than a minor amount of an additional component for enhancing the amorphous characteristics of densified articles produced by directing a stream of molten droplets at a repellent surface to produce the smooth surfaced and melt solidified particles having an average particle size of less than about ten micrometers.

Abstract: A fine aluminum metallurgical powder suitable for compacting and sintering into densified articles which includes a dispersed phase is produced by directing a stream of molten droplets at a repellent surface to produce smooth surfaced and melt solidified particles having an average particle size of less than about ten micrometers.

Abstract: A plasma spray powder comprising a uniform powder blend of silicon nitride and a plasma meltable metal produces a coating having some of the properties of silicon nitride.

Abstract: A fine powder is prepared by directing a high velocity stream of molten droplets into a cooling fluid to form rapidly solidified powder. The powder is subjected to comminution at an energy sufficient to fragment at least a portion of the particles which are not completely rapidly solidified. The fragmented particles are removed to give a powder containing a greater proportion of rapidly solidified particles than the original mixture.

Abstract: Metal carbide is reclaimed from scrap by sorting the scrap to separate pieces of cemented carbide having similar composition and grain size and treating the separated portion to form metal carbide grains which may be resintered with metal binder to obtain cemented carbides having grain characteristics similar to the starting material.

Abstract: Metal carbide is reclaimed from scrap by sorting the scrap to separate pieces of cemented carbide having similar composition and grain size and treating the separated portion to form metal carbide grains which may be resintered with metal binder to obtain cemented carbides having grain characteristics similar to the starting material.

Abstract: In a method for determining the grain size of a cemented carbide for a given quantity and composition of the metal binder, the grain size is determined as a function of the coercive force and quantity of metal binder.

Abstract: Plasma spray powders of molybdenum particles containing at least 0.5 weight percent oxygen and obtained by reacting molybdenum particles with oxygen or oxides in a plasma, form plasma spray coatings exhibiting hardnesses comparable to flame sprayed coatings formed from molybdenum wire and plasma coatings of molybdenum powder containing hardening alloy powders. Such oxygen rich molybdenum powders may be used to form wear resistant coatings, such as for piston rings.

Abstract: Free flowing powders such as for flame spray applications are produced by agglomerating finely divided material, classifying the agglomerates to obtain a desired size range, entraining the agglomerates in a carrier gas, feeding the agglomerates through a high temperature plasma reactor to cause at least partial melting of the particles, and collecting the particles in a cooling chamber containing a protective gaseous atmosphere, wherein the particles are solidified.

Abstract: Plasma flame spray coatings exhibiting improved hardness and wear resistance are produced from flame spray powders comprising spray dried agglomerates of finely divided molybdenum and alumina powder subparticles, wherein the diameters of the agglomerates are at least two times the maximum diameter of the subparticles.