Abstract: A method for refining a titanium metal containing ore such as rutile or ilmenite or mixtures to produce titanium ingots or titanium alloys and compounds of titanium involves production of titanium tetrachloride by processing the ore with a chlorinating procedure and removing various impurities by a distillation or similar procedures to form a relatively pure titanium tetrachloride. Thereafter, the titanium tetrachloride is introduced continuously into a reactor at the focal point of a plasma under atmospheric pressures of inert gas along with molten metallic reductant for the initial reduction of gas phase titanium tetrachloride into molten titanium drops which are collected in a set of skulled crucibles. Thereafter, further processing is carried out at atmospheric pressures in under inert gas where the titanium is heated by plasma guns to maximize titanium purity and, in a final optional stage, alloying compounds are added under the same controlled environment and high temperature conditions.

Abstract: An apparatus for thermal conversion of one or more reactants to desired end products includes an insulated reactor chamber having a high temperature heater such as a plasma torch at its inlet end and, optionally, a restrictive convergent-divergent nozzle at its outlet end. In a thermal conversion method, reactants are injected upstream from the reactor chamber and thoroughly mixed with the plasma stream before entering the reactor chamber. The reactor chamber has a reaction zone that is maintained at a substantially uniform temperature. The resulting heated gaseous stream is then rapidly cooled by passage through the nozzle, which “freezes” the desired end product(s) in the heated equilibrium reaction stage, or is discharged through an outlet pipe without the convergent-divergent nozzle. The desired end products are then separated from the gaseous stream.

Abstract: Methods of producing metal and alloy fine powders having purity in excess of 99.9%, preferably 99.999%, more preferably 99.99999% are discussed. Fine submicron and nanoscale powders discussed include various shapes and forms including spheres, rods, whiskers, platelets and fibers. The use of surfactant, emulsifying agents and capping dispersants in powder synthesis are presented. Compositions taught include nickel, copper, iron, cobalt, silver, gold, platinum, palladium, tin, zirconium, aluminum, silicon, antimony, indium, titanium, tantalum, niobium, zinc and others from the periodic table. The fine powders are useful in various applications such as biomedical, sensor, electronic, electrical, photonic, thermal, piezo, magnetic, catalytic and electrochemical products.

Abstract: Apparatus and methods for plasma-assisted melting are provided. In one embodiment, a plasma-assisted melting method can include: (1) adding a solid to a melting region, (2) forming a plasma in a cavity by subjecting a gas to electromagnetic radiation having a frequency less than about 333 GHz in the presence of a plasma catalyst, wherein the cavity has a wall, (3) sustaining the plasma in the cavity such that energy from the plasma passes through the wall into the melting region and melts the solid into a liquid, and (4) collecting the liquid. Solids that can be melted consistent with this invention can include metals, such as metal ore and scrap metal. Various plasma catalysts are also provided.

Abstract: A method for refining a titanium metal containing ore such as rutile or ilmenite or mixtures to produce titanium ingots or titanium alloys and compounds of titanium involves production of titanium tetrachloride as a molten slag, by processing the ore in a chlorination procedure and removing various impurities by a distillation or other procedure to form a relatively pure titanium tetrachloride (TiCl4). Thereafter, the titanium tetrachloride is introduced continuously into the focal point of a plasma reactor in a molten magnesium, sodium, hydrogen, lithium, potassium, rubidium, cesium, francium, beryllium, calcium, strontium, barium or radium environment for the initial reduction of gas phase titanium into molten titanium drops which are collected by a set of skulls.

Abstract: A method for synthesizing a nano-structured material, including four primary steps: (A) providing a reaction chamber wherein the nano-structured material is generated from at least a starting material selected from the group consisting of a metal, a metal alloy, a metal compound, and a ceramic; (B) operating a twin-wire arc nozzle, comprising two wires and a working gas being controllably fed into the chamber, to form an arc between two converging leading tips of the two wires to heat and melt the starting material at the leading tips for providing a stream of liquid droplets traveling in a predetermined direction (preferably vertically downward); (C) operating at least a second high energy source for producing a vaporizing zone adjacent to the arc and inside the chamber wherein the liquid droplets are vaporized to form vapor species; and (D) cooling the vapor species for forming the nano-structured material.

Abstract: A method and apparatus for optimized mixing in a common hearth in a plasma furnace. The apparatus provides a main hearth, a plurality of optional refining hearths, and a plurality of casting molds or direct molds whereby the refining hearths and molds define at least two separate ingot making lines. A feed chute provides raw material to the main hearth, whereby the feed chute is moveable to optimize its position during operation of the main hearth. Most particularly, the feed chute is moveable to provide better mixing, minimize skull build-up, and optimally place it opposite the overflow in use.

Abstract: Method for producing metallic nanoparticles. The method includes generating an aerosol of solid metallic microparticles, generating non-oxidizing plasma with a plasma hot zone at a temperature sufficiently high to vaporize the microparticles into metal vapor, and directing the aerosol into the hot zone of the plasma. The microparticles vaporize in the hot zone to metal vapor. The metal vapor is directed away from the hot zone and to the plasma afterglow where it cools and condenses to form solid metallic nanoparticles.

Abstract: The present invention relates to the production of ultrafine powders using a microwave plasma apparatus and chemical synthesis technique. Microwaves generated by a magnetron (1) are passed through waveguides (2) before they arrive at the head of a plasmatron (3). These high energy microwaves ionize a plasma gas, thus releasing large amounts of energy. The energy thus released is utilized to initiate and sustain chemical reactions between the desired elements being pumped in a spiral pattern into the plasmatron (3). The reaction products are quenched rapidly in a reactor column (4) into ultrafine powders.

Abstract: A process for synthesizing nanosized powders utilizes a hybrid exploding wire device containing a solid metal wire fuse in the bore of a tube that is open at each end. The ends of the fuse are connected to electrodes on the ends of the tube. The electrodes are designed to erode to maintain a heavy metal plasma. The bore may comprise a corresponding ceramic to be produced, and a microcrystalline powder of a corresponding ceramic may be retained within the bore. An electrical discharge vaporizes and ionizes the fuse. The tube confines the radial expansion of the plasma such that the plasma exits from both ends of the tube where it reacts with a suitable gas to form nanoscale particles. In addition, the plasma gas ablates and vaporizes a portion of the bore wall to contribute to the nanoceramic synthesis. Other alternatives include replacing the fuse with a thin conductive sheath or a consumable metal insert.

Abstract: The invention relates to a method for the extraction of metals from copper sulphide and/or copper iron sulphide ores with microbiological- and chemical-type leaching steps for dissolution of the metals, which comprises the following steps: 1) In a conversion step, prior to the leaching steps, the ores are converted to covellite, pyrites and admixed sulphides by the addition of sulphur, and 2) copper and other metals, noble metals and rare earths contained in the reaction product are extracted.

Abstract: The spheroidized hard material powders are produced by introducing a finely ground basic mixture of hard material into a thermal, inductively coupled high-frequency plasma so that at the same time a chemical conversion reaction to form an alloy and/or chemical reaction and spheroidization of the particles in the plasma take place. The hard material mixture may be powder, granules, or a suspension or any combination thereof. Hence, a mixture consisting of MexMy, wherein Me is a metal and M is a metalloid so that different metals and metalloids may be combined in the required metal-metalloid ratio is injected axially into an inductively coupled, high-frequency plasma with the aid of a carrier gas stream. The spheroidized hard material powder has excellent suitability for protection against wear.

Abstract: A gas generator disposal method capable of disposing of large quantities of gas generators safely, efficiently and without contamination of environments, and a system therefor, the method comprising releasing an air bag deploying gas from an unused gas generator (X) by applying a YAG laser beam (R) to an igniter (P) of the gas generator (X).

Abstract: An improved process for successful and homogeneous incorporation of ruthenium and iridium into titanium and titanium alloy melts, ingots, and castings via traditional melting processes (e.g., VAR and cold-hearth) has been developed. This result is achieved through the use of low-melting point Ti-Ru or Ti—Ir binary master alloys within the general composition range of ≦45 wt. % Ru and with a preferred composition of Ti-(15-40 wt. % Ru), or within the general composition range of ≦61 wt. % Ir and with a preferred composition of TI-(20-58 wt. % Ir). Primary features are its lower melting point than pure titanium, lower density than pure Ru and Ir metals, and the ability to be readily processed into granular or powder forms.

Abstract: A metal purification method and a metal refinement method in which metals of high purity can be easily refined and recovered without increasing the size of the purification and refining devices or complicating the operation. To this end, metals containing impurities are molten in a plasma arc containing active hydrogen to remove the impurities. If the metals contain ceramics inclusions, the metals are molten in a plasma arc containing active hydrogen and the ceramics inclusions are caused to float over the molten metal by exploiting the difference of density between the molten metal and the ceramics inclusions. The floating ceramics inclusions are decomposed and removed. For application to refining, the metal oxides are molten in a plasma arc containing active hydrogen so as to be reduced to metals.

Abstract: An ion source 2 has a heating furnace 4 for annealing a solid material 6 to generate a steam 8 and a plasma generator 16 for ionizing the steam 8 to generate a plasma 24. The ion source 2 is for generating ion beam. An indium trifluoride is used as said solid material which has been once heated at temperature in the range of 600° C. to lower than 1170° C., thereby enabling to generate the indium ion beam in a stable amount. For the solid material 6, In(OF)xF3-x (x is 1, 2 or 3) may be used.

Abstract: The present invention is concerned with a method for the production of fine and ultrafine powders of various materials such as metals, alloys, ceramics, composites etc., through a transferred arc plasma system. The method comprises vaporizing or decomposing the material in the plasma reactor, condensing the vapor in a quench tube comprising two sections, the first one for indirectly cooling or heating the vapor, and the second one for directly cooling the vapor. The powder is recovered in a conventional collection unit. The two step condensation in the quench tube allows a substantial control of powder properties like crystallinity, size distribution and mean particle size.

Abstract: Method and device to feed tuyeres in an electric furnace, the tuyeres comprising a central conduit to deliver a comburent gaseous substance and a peripheral conduit to deliver a cooling gaseous substance, the method providing to send to the central conduit a comburent mixture consisting of oxygen and neutral gas (N2, Ar, etc.) in defined percentages, the oxygen and the neutral gas being fed, for each of the tuyeres, to a mixing device with a high mixing capacity, at least the pressure of the neutral gas being able to be adjusted on the relative feed line so as to modulate the pressure of the mixture according to the characteristics of the melting process.

Abstract: Method for removing a portion of the binder phase from the surface of a substrate that is composed of particles of at least a first phase joined together by the binder phase, and wherein the surface is etched by contacting it with a gas flow of an etchant gas and a second gas. The second gas is one or more gases that will not react with the substrate or the removed binder phase and will not alter the oxidation state of the substrate during etching.

Abstract: A fast quench reaction includes a reactor chamber having a high temperature heating means such as a plasma torch at its inlet and a restrictive convergent-divergent nozzle at its outlet end. Reactants are injected into the reactor chamber. The resulting heated gaseous stream is then rapidly cooled by passage through the nozzle. This “freezes” the desired end product(s) in the heated equilibrium reaction stage.