Abstract: An apparatus for producing ultrafine particles by arc energy characterized by disposing an electrode inclinedly as to a base material so as to generate a magnetic blow to arc, disposing a suction opening at the direction of the arc blown, and cooling vapors generated, followed by collection thereof can improve the production efficiency of ultrafine particles with a uniform particle size.

Abstract: A process for producing a mixed ultrafine powder, which comprises reacting at least two metals or ceramics in the molten state with hydrogen, nitrogen, oxygen, a mixture of hydrogen and nitrogen or a mixture of nitrogen and oxygen. Each said gas or gaseous mixture being activated with a hot plasma, in an atmosphere of hydrogen gas, nitrogen gas, oxygen gas, a gaseous mixture of hydrogen and nitrogen, a gaseous mixture of nitrogen and oxygen, or a gaseous mixture of any of said gases with an inert gas under a pressure of 50 torr to 3 atmospheres to form ultrafine particles of said at least two metals or ceramics afloat in the atmospheric gas, and thereafter mixing the floating ultrafine particles of the metals or ceramics by a gas current.

Abstract: A method and apparatus for producing ultrafine metal powders in which a laser beam is focused on the surface of a workpiece or feedstock and moved thereacross so as to create a cavity within the workpiece through melting and vaporization that contains the metal melted to form the cavity. A subsonic pulsating blast of inert gas is directed at the cavity to atomize the molten metal, rapidly cool the resulting droplets, and transport the droplets to a collection area. The cavity formed by the laser beam is a "keyhole" of deep cavity having a depth approximately three to four times greater than its width. The focal point of the laser beam is moved across the workpiece at a rate from approximately 50 to 80 inches per minute to ensure that the molten metal remains in the cavity prior to the gas atomization.

Abstract: Preparation of products having a tubular portion comprising electrostatically spinning a fiberizable liquid, the electrostatic field being distorted by the presence of an auxiliary electrode, preferably so as to encourage the deposition of circumferential fibers.

Abstract: A process for producing ultrafine particles of a ceramic, which comprises heating a ceramic having substantially the same components as the final ultrafine ceramic particles, a metal constituting the metal component of the final ultrafine ceramic particles, a mixture of said ceramic with said metal or carbon, or a mixture of said metal with carbon by an arc plasma or a high frequency induction plasma generated in hydrogen, nitrogen, oxygen, a gaseous mixture of hydrogen and nitrogen, or a gaseous mixture of nitrogen and oxygen.

Abstract: A toroidal pile of raw material is contained in a toroidal melting pot provided in the lower portion of a furnace and a ring plasma torch is mounted over the toroidal pile of the raw material. A ring plasma arc, driven electromagnetically and rotating azimuthally between the torch and the pile, heats a certain portion of the pile intermittently and periodically. Fine grains are produced in such portion of the pile of raw material that is not heated directly by the plasma arc and collected through a discharge port provided around the major axis of the toroidal melting pot.

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: In a method wherein arcs are struck across a material to vaporize into ultra-fine particles and an electrode, thereby to manufacture the ultra-fine particles; the material to turn into the ultra-fine particles is arranged for at least either of the electrodes, and plasma currents are generated from the material and the electrode, whereby the formation rate of the ultra-fine particles per unit input is increased, and the material is formed in the shape of a rod or a wire, and a feeder capable of continuously supplying the material is disposed, whereby the ultra-fine particles can be continuously manufactured.

Abstract: When a particulate material under molten or dissolved state is atomized by means of a fluid nozzle or a rotary disc type atomizer, a high voltage is applied to obtain particles which are uniform in shape and, for example, spherical with a narrow particle size distribution. Further, if necessary, the particles obtained are subsequently encapsulated in the continuous step.

Abstract: Disclosed are methods, utilizing electromagnetic levitation, for producing low density, porous metal structures and hollow metallic spheres, using particulate material as a starting point. As an initial step, a porous article of sufficient green strength to be substantially self-supporting is formed of a particulate material containing at least one electrically-conductive metal. The green porous article is subjected to an electromagnetic field which has a field strength and frequency sufficient to levitate the green article in space against the force of gravity, and which has a frequency sufficient to induce in the article an eddy current of such intensity to produce heat sufficient to melt the electrically conductive metal, thereby entrapping the pores of the green article and any gases or non-electrically conductive particulate material contained therein. The next steps vary, depending on whether a porous metal structure or a hollow metallic sphere is to be produced.

Abstract: Large, uniform hollow spherical shells are produced by forming uniform size drops of heat decomposable or vaporizable material, evaporating the drops to form dried particles, coating the dried particles with a layer of shell forming material, and heating the composite particles to melt the outer layer and decompose or vaporize the inner particle to form an expanding inner gas bubble which expands the outer layer. By cycling the temperature and pressure on the hollow shells, spherical shells with uniform walls are produced.

Abstract: A process is provided for reducing the size and number of undesirable gauge bands in wound-up rolls of wide nonwoven sheet that is produced by a plurality of oscillating fiber streams depositing fiber on a moving receiver. The desired effect is accomplished by varying the oscillation frequency of the fiber streams by more than .+-.5% of the average oscillation frequency.

Abstract: A process for the preparation of polyurethane resins particularly suitable for electrostatic spinning which comprises forming a prepolymer of polyether glycol and a diisocyanate reacted in a molar ratio of about 1:2, and thereafter reacting the prepolymer with additional diisocyanate and a diol extender, the final molar ratio of the polyether, isocyanate and diol reactants being approximately 1:3.7:2.5. The reaction is conducted in an organic solvent at a temperature of about 45.degree. C. to obtain a polymer having an inherent viscosity of from about 2.0 to 2.4 in a solution of 25 to 30 percent solids. The solution is diluted to about 15 percent solids prior to spinning.

Abstract: An apparatus for manufacturing metallic fine particles by use of at least one arc-discharging section located in a hollow interior cavity of a rotary body. Metallic material is dropped into the rotary body during rotation thereof. The metallic material is melted and driven centrifugally through an outlet where it impinges upon a stationary cooled wall of a surrounding casing. When the melted material strikes the cooled wall, the melted material forms small particles. These small particles are then withdrawn through an outlet in the casing.

Abstract: A rotary electrode apparatus for producing metal powders including a chamber for maintaining a controlled atmosphere. A first electrode is mounted in the chamber and a second consumable disc electrode is mounted in the chamber confronting the first electrode. An electric arc is struck between the first electrode and a circumferential portion of the disc electrode in order to melt the circumferential portion. The disc electrode is rotated at sufficient speed to enable melting of the circumferential portion of the disc and spinning off of melted portions of the disk.

Abstract: A method of producing rapidly solidified metal powder utilizes a spinning metal source and a laser beam to melt the surface layer of the source and atomize it. The laser beam is directed at a glancing angle along the surface of the spinning metal source. The source spins at a high speed of 10,000-30,000 revolutions per minute. The atomized metal is solidified rapidly in an inert gas atmosphere. Very high cooling rates up to 10.sup.6 .degree. C. per second can be achieved. Very small and uniformly distributed particles of rapidly solidified metal can be obtained having a narrow particle size distribution from about 50-150 microns and typically having a high percentage of the particles at a particle size of below 100 microns.

Abstract: A process for producing fine particles of a metal or alloy, which comprises contacting a molten metal or alloy with activated hydrogen gas thereby to release fine particles of the metal or alloy having a diameter of less than 10 microns from the molten metal or alloy.

Abstract: A method for producing atomized metal particles, particularly of titanium-base alloys and superalloys, that are free from contamination by foreign material; this is achieved by providing a rod of the metal to be atomized and contacting an end portion of the rod with a plasma arc gas jet which simultaneously melts and atomizes the metal from the rod to form the atomized particles and preventing contamination of the particles.

Abstract: A device for the production of a non-woven product from a fluid dielectric substance, comprising a first electrode, means for leading this electrode along a closed path, driving means to move this electrode along this path, coating means for coating this electrode with the said substance opposite a first portion of the said path, a second electrode whose surface is relatively extensive with regard to the first electrode, located opposite a second portion of the said path, an electrostatic generator connected to one of the said electrodes to establish a potential difference between them so as to create an electrostatic field capable of acting on the said substance to form a plurality of fibers in the direction of the said second electrode, characterized in that it comprises two endless transport bands mounted respectively around guide means defining two closed parallel trajectories passing near the coating means and the said second electrode, these bands being connected to the said driving means so as to move

Abstract: The disclosure embraces a method of and apparatus for processing heat-softenable materials, such as glass, to form fibers or filaments from the streams of material and more particularly effecting successive distortions, oscillations or vibrations of the streams of glass by directing streams or jets of liquid for cooling or quenching the streams of glass at the region of formation of the fibers or filaments for establishing successive kinks, bends or crimps in the attenuated fibers or filaments, and delivering or conveying by the quenching streams of liquid or other streams of liquid powdered or particulate materials or metals for combining with, coating or reacting with the glass of the streams at the region of formation of the fibers or filaments for producing combined metal and glass fibers or filaments or coating the glass fibers or filaments with metals or other materials and utilizing electric current potential applied to the streams of liquid entraining metal or other particulate materials for establish

Abstract: Amorphous or microcrystalline alloy powder is prepared by the rapid quenching of ultrafine metallic spheroids generated from the molten metal state. The molten metal droplets are formed when an intense electric field (10.sup.5 V/cm) is applied to the surface of liquid metal held in a suitable container. The interactions between the intense electric field and liquid surface tension disrupts the metal surface, resulting in a beam of positively charged droplets. The liquid metal spheres generated by this electrohydrodynamic process are subsequently cooled by radiative heat transfer. Rapid cooling of the droplets may be accomplished by heat transfer to a low pressure gas by free molecular heat conductivity. Quenching rates exceeding 10.sup.6 .degree.K./sec are possible using this technique. Thin film coatings are prepared by electrohydrodynamically spraying a beam of charged droplets against a target (substrate). The target can be electrically controlled to effect the charged particles impact.

Abstract: An apparatus is disclosed for manufacturing splat foils by disintegration and rapid solidification of metallic melts. The apparatus has a self-consuming electrode disposed above a rotatable counter electrode. Attached to the counter-electrode is a conical plate which is cooled by a fluid circulating through its interior. The application of electrical energy to the electrodes causes the self-consuming electrode to melt and drop melt droplets onto the rotating counter-electrode. Centrifugal force causes the melt droplets to fly off the counter-electrode and contact the conical plate at which point they are rapidly cooled to form thin foils. A housing surrounds the electrodes and conical plate to collect the cooled foils and to permit the apparatus to operate in an inert atmosphere, if desired.

Abstract: A stream of molten metal from a supply is impinged upon an electrode while an electrical potential is impressed between the supply and the electrode. The zone of impingement becomes a stable electric arc in which the stream is atomized. A carrier gas intersects the spray and removes heat from the metal particles.

Abstract: A solution of elastomeric polyurethane in a volatile solvent is centrifugally sprayed onto a base in a strong electrostatic field to form long fibers that are swept across the base and deposited thereon in generally straight condition, overlapping and adhered to previously deposited fibers. Novel fibrous sheets of high strength are thus produced. The intersecting fibers may be ribbon-like.

Abstract: High-purity metal powder is made by the electron beam melting of a starting material in rod form in a vacuum wherein the molten metal is momentarily caught on a spinning plate rotating at high speed and flung therefrom and thereafter solidified by cooling. The metal on the spinning plate is bombarded with an electron beam that is so focused and periodically deflected that its focal spot is many times smaller than the diameter of the spinning plate. The beam deflection between the rotational center of the spinning plate and its marginal area is performed such that the spinning plate is scanned in a zone that extends radially of the axis of rotation of the spinning plate and is small in relation to its diameter. Cooling of the metal particles to the point of solidification is accomplished by radiation loss.

Abstract: A non-woven cellulose ester fibrous filter sheet material comprising cellulose ester staple fibers and cellulose ester fibrets which exhibits improved filtration properties and the method of its preparation.

Abstract: Uniform particles are produced by introducing a laminar stream of a core liquid into a laminar flowing body of an immiscible sheath liquid. The core liquid or the sheath liquid, or both liquids, can contain one or more materials dispersed (dissolved or suspended) in them from which the uniform particles are formed. The two liquids and the dispersed material are expelled from a nozzle to form a liquid jet. The liquid jet is disturbed at a uniform, periodic rate to form liquid droplets which contain a uniform amount of the core liquid, the sheath liquid and the dispersed material. The droplets are collected and held in a catch liquid until the core and the sheath liquid in each droplet have diffused into the catch liquid leaving the uniform particles formed from the dispersed materials. There can be more than one sheath liquid which can also contain one or more materials dispersed in it.

Abstract: In a process for the production of fibre filters, the fibre material is sprayed electrostatically from the liquid state and deposited as a fibre fleece on a conductive support. The starting materials used are solutions of high polymers in readily volatile solvents. The filters obtained have substantially improved properties.

Abstract: Method for producing small hollow spheres of glass, metal or plastic, wherein the sphere material is mixed with or contains as part of the composition a blowing agent which decomposes at high temperature (T .gtorsim. 600.degree. C). As the temperature is quickly raised, the blowing agent decomposes and the resulting gas expands from within, thus forming a hollow sphere of controllable thickness. The thus produced hollow spheres (20 to 10.sup.3 .mu.m) have a variety of application, and are particularly useful in the fabrication of targets for laser implosion such as neutron sources, laser fusion physics studies, and laser initiated fusion power plants.

Abstract: A method of preparing a porous sheet product which comprises the step of introducing a spinning liquid comprising an organic fibre forming polymeric material into an electric field whereby fibres are drawn from the liquid to an electrode and collecting the fibres so produced upon the electrode. PTFE and other fluorinated polymer mats produced by the electrostatic process are useful as electrolytic cell diaphragms, battery separators etc.

Abstract: An apparatus and method for providing a stream of molten metal from a metallic ingot wherein a quantity of the molten metal from the melted ingot is maintained at an established level within the chamber of the apparatus. It is further heated to an established temperature to then facilitate passage of the molten material through the apparatus's orifice.

Abstract: In the manufacture of metal and alloy powders in the form of small diameter spheres whose shape and diameter must be maintained within narrow limits, a substantially cylindrical solid electrode of the material from which the powder is to be made is rotated at high speed about its longitudinal axis and one end of the electrode is heated to fusion point, the molten material being sprayed therefrom under centrifugal forces in the form of small diameter spheres, wherein fusion of the one end of the electrode is obtained by means which produce a local fusion zone on the end surface of the electrode and means for causing the local fusion zone to move along a spiral path on the end surface of the electrode as the electrode rotates.

Abstract: An agglomerate of silicon and silicon base alloy particles having an in situ formed matrix of alkali metal silicate.

Abstract: In preferred form, the inventive concept utilizes a carbon arc plasma flame assembly wherein magnetic ore particles are fed to the plasma flame assembly in the presence of a controlled, gaseous atmosphere. The plasma flame assembly comprises a cathode and at least two carbon anodes to which is fed oxygen gas in a controlled amount. Upon contact with the plasma flame, the ore particles become molten droplets which fall by gravity into a spheroidization column having a controlled atmosphere. As the molten droplets fall, they cool and become spheroidal particles. The chamber wherein the heating occurs is substantially sealed and is initially purged with inert gas. In addition, the spheroidization column is fitted with an exhaust system which maintains the integrity of the processing atmosphere and that of the spheroidized particles.

Abstract: A process for producing high purity metal powders in which a metal or metal alloy of the desired composition is molten and introduced into a chamber in the form of a stream of a controlled cross sectional area which is fragmentized into a plurality of molten droplets by the impingement of a transversely excited laser having a preselected power to achieve the desired magnitude of fragmentation. The resultant droplets are cooled during their free-fall through the chamber and the solidified metal powder is subsequently recovered from the bottom of the chamber.

Abstract: A method for producing metal and alloy particles from an article thereof wherein the article is first diffused with a source of gas, such as hydrogen, and then subjected to localized heating to melting temperature. Upon localized melting the diffused gas within the article is liberated to produce an atomizing effect upon the melted material. This atomized material is then cooled sufficiently rapidly to form discrete particles which are then collected for further use, such as in powder metallurgy applications.

Abstract: In a process for the production of fiber filters, spinning solutions are electrostatically sprayed and deposited continuously onto a gas-permeable band-form support. The band-form support travels successively through several spray zones and is always guided from one spray zone into the next below the spray electrodes. Row arrangements of rotating rings dipping into the spinning liquid are used as the spray electrodes, the rings of one row lying in one plane.

Abstract: An electric arc which is struck between an electrode and the surface of a pool of molten material rotates under the influence of a magnetic field to thereby free liquid particles from the surface of the pool. The particles produced are quenched in an adjacent inert atmosphere or solidified in a vacuum and become powder. This powder is then collected conveniently.

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: High purity metallic powder is made from high purity metallic rod by positioning the rod above a horizontally oriented, cooled and rotating electrode. An electric potential is applied between the rod and the electrode so that the electrode end porixmate the disc is progressively melted down. Molten droplets are thrown off the disc by centrifugal forces onto a cooled, rotating, concave shield which intercepts the trajectory of the droplets. As the droplets contact the cooled shield they solidify and are deflected into a collector. The melting and cooling operations are performed in a controlled atmosphere, e.g., in a vacuum.

Abstract: Small particles of metal, such as those used in making powder metal compacts, are produced by feeding the end of a metal wire or rod against the edge of a rotating disc and causing a direct electrical current to flow through the wire and disc. This melts the end of the wire and also creates a magnetic field about the wire. The rotation of the disc breaks the electrical contact and forms an arc which causes additional melting of the wire. Contact between the wire and disc takes place within a second electromagnetic field. Continuously advancing the end of the wire causes the intermittent making and breaking of electrical contact. The interaction of the two magnetic fields causes the molten particles to be removed from the area of contact. Means are provided for cooling and collecting the metal particles and for preventing the accumulation of solidified metal particles on the electromagnet or the rotating disc. Vacuum conditions may be used, thus producing a powder of high purity.