Abstract: A process for producing metals, alloys and metal powders includes providing a feed material; heating the feed material in a melting hearth into a molten metal; and reducing oxygen in the molten metal using a reactive gas in an ionized or unionized state and an oxygen scavenging reaction wherein reaction sites in the molten metal containing oxygen react with the reactive gas. A first system configured to perform a process for producing metals and alloys includes a melting hearth and a heat source system in a melting chamber configured to melt a feed material into a molten metal for atomization, casting or further processing. A second system configured to perform a process for producing metal powders includes a foundry system configured to melt a feed material into a molten metal and an atomization system configured to atomize the molten metal into a metal powder comprised of metal particles.

Abstract: A melting hearth includes high temperature walls, a melting cavity having a specific topography, and conformal fluid cooling passages configured to provide a flow path for a cooling fluid that is substantially parallel to the topography of the melting cavity. In addition, the topography of the melting cavity mirrors a heat signature of a heat source used to melt a feed material in the melting hearth into a molten metal. A cold hearth melting system includes the melting hearth, a magnetic stirring system, the heat source having the heat signature, a tilting mechanism for tilting the melting hearth to a desired tilt angle, and a fluid cooling system having a fluid source in flow communication with the conformal fluid cooling passages. A process for producing high temperature metal alloys uses the cold hearth melting system and an algorithm for controlling the pouring of the molten metal from the melting hearth.

Abstract: A method for producing a stainless steel powder by water atomization including the steps of providing a molten metal of having a chemical composition, subjecting a stream of the molten metal to water atomization, recovering the obtained stainless steel powder. A sintered duplex stainless steel, wherein the steel has a composition, wherein the microstructure of the sintered duplex stainless steel is characterized by austenite phase precipitated in ferrite phase.

Abstract: Embodiments of the present invention may provide a new stainless steel powder suitable for manufacturing of duplex sintered stainless steels. Embodiments of the present invention may also relate to a method for producing the stainless steel powder, the duplex sintered stainless steel as well as methods for producing the duplex sintered stainless steel.

Abstract: A coated iron powder including a core of precursor iron powder, wherein the iron powder is reduced or electrolytic iron powder; a first coating including a first polymer and a first pigment, wherein the coating has a thickness of thickness of 5 to 30 ?m; a coating of an adjuvant, wherein the adjuvant includes ascorbic acid; and a second coating including a second polymer and a second pigment, wherein the coating has a thickness of thickness of 5 to 30 ?m.