Abstract: A biaxially textured alloy article having a magnetism less than pure Ni includes a rolled and annealed compacted and sintered powder-metallurgy preform article, the preform article having been formed from a powder mixture selected from the group of ternary mixtures consisting of: Ni powder, Cu powder, and Al powder, Ni powder, Cr powder, and Al powder; Ni powder, W powder and Al powder; Ni powder, V powder, and Al powder; Ni powder, Mo powder, and Al powder; the article having a fine and homogeneous grain structure; and having a dominant cube oriented {100}<100> orientation texture; and further having a Curie temperature less than that of pure Ni.

Abstract: The invention provides a process for forging a titanium-based material comprises the steps of: preparing a titanium-based sintered workpiece including at least one of ceramics particles and pores in a total amount of 1% or more by volume, the ceramics particles being thermodynamically stable in a titanium alloy; and heating the workpiece to a forging temperature and forging the same. In the production process, the pores or the ceramics particles inhibit the grain growth during forging. Accordingly, it is possible to carry out the forging at a relatively high temperature at which the titanium-based material exhibits a small resistance to deformation. Moreover, the titanium-based material can maintain an appropriate microstructure even after the forging. Consequently, the impact value and the fatigue strength are inhibited from decreasing.

Abstract: A coated cemented carbide tool, and a method for making the same, wherein the as-sintered substrate is formed by sintering in an atmosphere having at least a partial pressure and for a part of the time a nitrogen partial pressure.

Abstract: The thermal conductivity, thermal conductivity, of a sintered copper/refractory metal composite having a maximum porosity of about 1% is greatly improved when the composite contains phosphorus and sintering aid in a specified weight ratio, “phosphorus/sintering aid ratio.” The copper/refractory matrix composite herein comprises, by weight, from about 5% to about 30% copper, from about 0.2% to about 0.6% sintering aid, from about 0.08% to about 0.3% phosphorus, the remaining metal is refractory metal. The phosphorus to sintering aid ratio ranges from about 0.25 to about 0.55. In one embodiment of the invention the sintering aid contains cobalt and the refractory metal is tungsten.

Abstract: There is provided a method of making a high-melting metal powder which has high purity and excellent formability and, particularly, of a metal powder of spherical particles made of Ta, Ru, etc. having a higher melting point than iron. There is also provided a target of high-melting metal or its alloy, which is made by the sintering under pressure of these powders and which has high purity and a low oxygen concentration and shows high density and a fine and uniform structure. A powder metal material mainly composed of a high-melting metal material is introduced into a thermal plasma into which hydrogen gas has been introduced, thereby to accomplish refining and spheroidizing. Further, an obtained powder is pressed under pressure by hot isostatic pressing, etc.

Abstract: An object of the present invention is to provide a niobium sintered body free of reduction in the CV value, a niobium powder for use in the manufacture of the niobium sintered body, and a capacitor using the niobium sintered body. A niobium powder of the present invention has niobium and tantalum, where the tantalum is present in an amount at most of about 700 ppm by mass. A sintered body and a capacitor each is manufactured using the niobium powder.

Abstract: A method to agglomerate metal particles such as tantalum and niobium powders is described which includes combining a volatilizable or vaporizable liquid with the particles to form wet particles; compacting the wet particles; drying the compacted wet particles to form a cake; and heat treating the cake to form the agglomerated particles. Also described are agglomerated particles obtained by this method and further, particles, preferably tantalum or niobium powder, having a flow rate of at least about 65 mg/sec and/or an improved pore size distribution, and/or a higher Scott Density. Capacitors made from tantalum powder and niobium powder are also described.

Abstract: A sintered alloy composition for automotive engine valve seats, and a method for producing the same, are described. An iron base sintered alloy composition comprising vanadium carbide particles, Fe—Co—Ni—Mo alloy particles, and Cr—W—Co—C alloy particles in which the composition is dispersed in a structure of sorbite is particularly suitable for use as materials of valve seats for automotive engines which requires excellent wear resistance, high-performance, high-rotation-speed, and low-fuel-consumption.

Abstract: Metal powder Ta and/or Nb, with or without one or metals from the group Ta, Nb, Ti, Mo, W, V, Zr and Hf, is made in a fine powder form by reduction of metal oxide by contact with a gaseous reducing agent, preferably an alkaline earth metal, to near complete reduction, leaching, further deoxidation and agglomeration, the powder so produced being sinterable to capacitor anode form and processable to other usages.

Abstract: The invention concerns a method of improving the properties of a hydrogen storage alloy powder for a negative electrode of a rechargeable nickel hydride battery. The method comprises the steps of hydriding a powdered alloy starting material, oxidising the obtained hydride alloy powder and washing the oxidised powder. The invention also concerns the obtained powder.

Abstract: A titanium-based composite material according to the present invention is characterized in that it comprises: a matrix containing a titanium (Ti) alloy as a major component, and titanium compound particles and/or rare-earth element compound particles dispersed in the matrix, wherein the matrix contains 3.0-7.0% by weight of aluminum (Al), 2.0-6.0% by weight of tin (Sn), 2.0-6.0% by weight of zirconium (Zr), 0.1-0.4% by weight of silicon (Si) and 0.1-0.5% by weight of oxygen (O), the titanium compound particles occupy 1-10% by volume, and the rare-earth element compound particles occupy 3% by volume or less. With this arrangement, it is possible to obtain a titanium material, which is good in terms of the heat resistance, hot working property, specific strength, and so on.

Abstract: Tungsten powder is mixed with a second powder metal and a binder to be used as small arms projectiles and shot pellets for use in shot guns which is cost effective to produce and which can perform ballistically. Ballistic performance equal to or superior to that of lead would be offered by a material having a specific gravity equal to or greater than lead. The non-toxic projectiles are manufactured in a cost-effective process; yet still produces projectiles and shot pellets that can perform ballistically. This projectile composition can perform substantially as well as lead and lead alloys or better without the need to fabricate the composition from a high temperature molten state which requires large amounts of energy input. In one particular embodiment of the invention, the tungsten powder is blended with iron powder and Portland Cement for constructing projectiles. The tungsten, iron and Portland Cement (W/Fe Portland cement) shot provides a satisfactory substitute for lead shot.

Abstract: An object of the present invention is to provide a niobium sintered body free of reduction in the CV value, a niobium powder for use in the manufacture of the niobium sintered body, and a capacitor using the niobium sintered body. A niobium powder of the present invention has niobium and tantalum, where the tantalum is present in an amount at most of about 700 ppm by mass. A sintered body and a capacitor each is manufactured using the niobium powder.

Abstract: A method of making sheet bar and other precursors of formed products to be made by extensive working. The method includes providing a powder metal, preferably under 100 PPM oxygen content of non-spherical particles, compacting the powder into a coherent precursor form of at least 100 pounds, whereby a precursor is provided enabling extended fabrication to a finished product form. The finished product is resistant to breakup in fabrication due to oxide inclusion effect and produces a low oxygen end product. The method can process multiple species of metals that include at least one higher melting metal and one lower melting metal to produce an alloy or micro-composite of the metals as worked, where one metal is preferably a refractory metal (Ta, Nb, W, Wo, Zr, Hf, V and Re). The process is controlled to cause powder of the higher melting metal to be extended into a fibrous form.

Abstract: Tungsten powder is mixed with a second powder metal and a binder to be used as small arms projectiles and shot pellets for use in shot guns which is cost effective to produce and which can perform ballistically. Ballistic performance equal to or superior to that of lead would be offered by a material having a specific gravity equal to or greater than lead. The non-toxic projectiles are manufactured in a cost-effective process; yet still produces projectiles and shot pellets that can perform ballistically. This projectile composition can perform substantially as well as lead and lead alloys or better without the need to fabricate the composition from a high temperature molten state which requires large amounts of energy input. In one particular embodiment of the invention, the tungsten powder is blended with iron powder and Portland Cement for constructing projectiles. The tungsten, iron and Portland Cement (W/Fe Portland cement) shot provides a satisfactory substitute for lead shot.

Abstract: A biaxially textured alloy article having a magnetism less than pure Ni includes a rolled and annealed compacted and sintered powder-metallurgy preform article, the preform article having been formed from a powder mixture selected from the group of mixtures consisting of: at least 60 at %Ni powder and at least one of Cr powder, W powder, V powder, Mo powder, Cu powder, Al powder, Ce powder, YSZ powder, Y powder, Mg powder, and RE powder; the article having a fine and homogeneous grain structure; and having a dominant cube oriented {100}<100>orientation texture; and further having a Curie temperature less than that of pure Ni.

Abstract: A biaxially textured alloy article having a magnetism less than pure Ni includes a rolled and annealed compacted and sintered powder-metallurgy preform article, the preform article having been formed from a powder mixture selected from the group of mixtures consisting of: at least 60 at % Ni powder and at least one of Cr powder, W powder, V powder, Mo powder, Cu powder, Al powder, Ce powder, YSZ powder, Y powder, Mg powder, and RE powder; the article having a fine and homogeneous grain structure; and having a dominant cube oriented {100}<100>orientation texture; and further having a Curie temperature less than that of pure Ni.

Abstract: A method for producing a contact material made of copper and chromium in a proportion of 40 to 75 wt.-% copper and 25 to 60 wt.-% of chromium for contact pieces for vacuum switch devices by pressing the powder mixture, sintering and infiltrating the compact and subsequent reshaping into a semi-finished contact material product having a density which corresponds to at least 99% of the theoretical density, as well as to contact pieces made of this semi-finished contact material product.

Abstract: Non-evaporable getter alloys containing zirconium, vanadium, iron, manganese and one or more elements selected among yttrium, lanthanum and Rare Earths are described, having improved features of gas sorption, particularly of nitrogen, with respect to the known getter alloys.

Abstract: A niobium sintered body for a capacitor, which exhibits an LC value of not larger than 300 &mgr;A/g as measured after an electrolytic oxide film is formed thereon. The sintered body preferably exhibits a product (CV) [i.e., a product of capacity (C) with electrolysis voltage (V)] of at least 40,000 &mgr;F·V/g. The sintered body is produced by sintering a niobium powder containing at least one niobium compound selected from niobium nitride, niobium carbide and niobium boride. A capacitor manufactured from the sintered body has a large capacity per unit weight and good leak current characteristics. Especially, a sintered body made of a niobium powder having a large average degree of roundness has a relatively large porosity and a good packed density, and a capacitor manufactured from this sintered body has a large capacity and good withstand voltage characteristics.

Abstract: An alloy feedstock for semi-solid metal injection molding. The alloy feedstock is an alloy material in particulate form and has a heterogeneous structure, a temperature range at 20% of the height of the peak of the main melting reaction greater than 40° C., and having a ratio of the height of the peak of the eutectic reaction to the height of the main melting reaction of less than 0.5.

Abstract: There is provided a method of making a high-melting metal powder which has high purity and excellent formability and, particularly, of a metal powder of spherical particles made of Ta, Ru, etc. having a higher melting point than iron. There is also provided a target of high-melting metal or its alloy, which is made by the sintering under pressure of these powders and which has high purity and a low oxygen concentration and shows high density and a fine and uniform structure. A powder metal material mainly composed of a high-melting metal material is introduced into a thermal plasma into which hydrogen gas has been introduced, thereby to accomplish refining and spheroidizing. Further, an obtained powder is pressed under pressure by hot isostatic pressing, etc.

Abstract: Methods for producing medium-density articles from recovered high-density tungsten alloy (WHA) material, and especially from recovered WHA scrap. In one embodiment of the invention, the method includes forming a medium-density alloy from WHA material and one or more medium- to low-density metals or metal alloys. In another embodiment, medium-density grinding media, such as formed from the above method, is used to mill WHA scrap and one or more matrix metals into particulate that may be pressed and, in some embodiments, sintered to form medium-density articles therefrom.

Abstract: A unique iron base alloy for wear resistant applications, characterized in one aspect by its hardening ability when exposed to a certain temperature range, is useful for valve seat insert applications. The alloy also possesses excellent wear resistance, hot hardness and oxidation resistance. The alloy comprises less than 0.1 wt % carbon; about 18 to about 32 wt % molybdenum, about 6 to about 15 wt % chromium, about 1.5 to about 3% silicon, about 8 to about 15 wt % cobalt and at least 40% iron, with less than 0.5 wt % nickel. In another aspect, for lower temperature applications, the cobalt is optional, the nickel content can be up to 14 wt %, but the molybdenum must be in the range of about 29% to about 36%. In one further aspect, for higher temperature applications, the cobalt is optional, but may be used up to 15 wt %, nickel must be used at a level of between about 3 and about 14 wt %, and the molybdenum will be in the range of about 26 to about 36 wt %.

Abstract: In an NiMnGa alloy represented by the chemical formula of Ni2+XMn1−X Ga, a composition ratio parameter X (mol) is selected within a range of 0.10≦X≦0.30. With this composition, the finish point of the reverse transformation of the martensitic transformation can be selected to a desired temperature within the range between −20° C. and 50° C., while the Curie point is also selected to a desired temperature within the range between 60° C. and 85° C. The alloy has the shape memory effect by the martensitic transformation and the reverse transformation. Furthermore, the alloy is induced with the reverse transformation by application of an external magnetic field at the martensite phase to exhibit the shape recovery.

Abstract: The invention relates to a method of preparing metal powder comprising: preparing a simple or mixed oxalate of one or more metals formed of particles with needle-like morphology having a mean acicularity ratio (length/diameter) of from 4 to 20, and a length of from 5 to 10 microns and converting said oxalate to metal or metal alloy powder by reducing treatment with gaseous hydrogen. The conversion of said oxalate can be carried out by decomposing said oxalate, in air, to an oxide and then reducing said oxide to metal or metal alloy. The metal is chosen from among the rare earth metals and the transition metals, preferably from among iron, cobalt, and nickel. The method is particularly suitable for making iron powder metal having a spongy and filament-like microstructure which makes it suitable for use in heating composition for thermo-piles. In addition, the invention relates to metal compacts unstoved or annealed which are obtained by applying compaction pressure to the powders according to the invention.

Abstract: The present invention relates to a powdered niobium for a capacitor, characterized in that the content of each of the elements such as iron, nickel, cobalt, silicon, sodium, potassium and magnesium is about 100 ppm by weight or less or that the total content thereof is about 350 ppm by weight or less is used, a sintered body thereof, a sintered body comprising niobium monoxide crystal and/or diniobium mononitride crystal, a capacitor using the sintered body and the production method of the capacitor.

Abstract: A niobium powder for forming an anode of a solid electrolytic capacitor which improves the defects in the prior art that an average particle diameter is too small, niobium is consumed as an oxide film in anodic oxidation step and the effective electrode surface area decreases. In the improved powder, for primary particles, the average particle diameter is 0.10-2 &mgr;m, the geometric standard deviation of particle size distribution exceeds 1.4 and the degree of sphericity is 2 or less. Anodes for solid electrolytic capacitors which are suitable for the use of super-high capacity can be manufactured by using the improved powder.

Abstract: A pellet for use in electrolytic capacitors is comprised of a powder selected from one of Tantalum and Niobium. The pellet is porous, free from oxygen, annealed by heat, and diffused with nitrogen with all these attributes being achieved in an oxygen free environment. The method of producing the pellet involves the steps of taking a powder selected from one of Tantalum and Niobium pressing the powder into a self-contained pellet; removing any oxygen in the pellet; annealing the pellet; and subjecting the pellet to nitrogen gas so that the nitrogen diffuses into the pellet to reduce DLC, with all these steps taking place in an oxygen free environment.

Abstract: A low cost titanium, titanium alloy material, or Ti matrix composite comprising clean and divided titanium turnings that are blended with titanium, titanium alloy powder, and/or ceramic powder and consolidated is provided. A method of making the material is also provided. The low cost material is formed into preshapes, such as a billet, which is subsequently used as feedstock for extrusion, forging, casting, or rolling.

Abstract: A highly reliable sintered compact which can be readily and safely produced, and a method for producing such sintered compact are provided. The sintered compact is preferably formed into a heat sink 1 which comprises a heat sink main body 2. The heat sink main body 2 comprises a substrate 3, a plurality of projections 4 integrally formed with the substrate 3 on its heat dissipation surface, and a molded frame 5 integrally formed with the substrate 3 to surround the projections 4. On each corner of the substrate 3 is formed a circular molded hole 6. The opposite surface of the substrate 3 is formed into a contacting surface which is adapted to be in contact with the heat generating semiconductor chip, and this contacting surface is surface treated, for example, by plating. The sintered compact is produced from metal powders, and it comprises at least one metal selected from tungsten and molybdenum and 2 to 50% by weight of silver.

Abstract: A method for producing a compact of rare earth alloy powder of the present invention includes: a powder-filling step of filling rare earth allow powder in a cavity formed by inserting a lower punch into a through hall of a die of a powder compacting machine; and a compression step of pressing the rare earth alloy powder while applying a magnetic field, the steps being repeated a plurality of times. When the (n+1)th (n is an integer equal to or more than 1) stage compression step is to be carried out, the top surface of a compact produced in the n-th stage compression step is placed at a position above the bottom surface of a magnetic portion of a die.

Abstract: A niobium powder having a nitrogen content of about 500-about 7,000 ppm by weight, and having a mean particle diameter of at least about 0.2 &mgr;m and less than about 3 &mgr;m. Preferably the niobium powder has a reduced content of impurities. A sintered body of the niobium powder. This sintered body generally has a specific leakage current index of not more than about 400 [pA/(&mgr;F·V)]. The capacitor having (i) an electrode composed of the sintered body, (ii) a counter electrode and (iii) a dielectric intervening between the two electrodes exhibits good leakage current characteristics.

Abstract: A method for making a nickel/silicon sputter target, targets made thereby and sputtering processes using such targets. The method includes the step of blending molten nickel with sufficient molten silicon so that the blend may be cast to form an alloy containing no less than 4.5 wt .% silicon. Preferably, the cast ingot is then shaped by rolling it to form a plate having a desired thickness. Sputter targets so formed are capable of use in a conventional magnetron sputter process; that is, one can be positioned near a cathode in the presence of an electric potential difference and a magnetic field so as to induce sputtering of nickel ion form the sputter target onto the substrate.

Abstract: A powder composition for a capacitor comprising a tantalum or niobium and a compound having a silicon-oxygen bond, at least a part of which may be nitrided and which has an average particle size of from about 0.1 to about 5 &mgr;m; a sintered body using the composition; and a capacitor constituted by the sintered body as one part electrode, and another part electrode. A capacitor favored with high reliability, lower dissipation level of power and smaller deterioration of capacitance than conventional tantalum capacitors using tantalum can be produced by using a sintered body of the powder composition for a capacitor.

Abstract: A flaked niobium powder is disclosed as well as electrolytic capacitors formed from the flaked niobium powders. Niobium powders having a BET surface area of at least about 0.50 m2/g are also disclosed and capacitors made therefrom, as well as niobium powders doped with an oxygen content of at least 2,000 ppm. Methods to reduce DC leakage in a niobium anode are also disclosed.

Abstract: High purity refractory metals, valve metals, refractory metal oxides, valve metal oxides, or alloys thereof suitable for a variety of electrical, optical and mill product/fabricated parts usages are produced from their respective oxides by metalothermic reduction of a solid or liquid form of such oxide using a reducing agent that establishes (after ignition) a highly exothermic reaction, the reaction preferably taking place in a continuously or step-wise moving oxide such as gravity fall with metal retrievable at the bottom and an oxide of the reducing agent being removable as a gas or in other convenient form and unreacted reducing agent derivatives being removable by leaching or like process.

Abstract: The present invention relates to a powdered niobium for a capacitor, characterized in that the content of each of the elements such as iron, nickel, cobalt, silicon, sodium, potassium and magnesium is about 100 ppm by weight or less or that the total content thereof is about 350 ppm by weight or less is used, a sintered body thereof, a sintered body comprising niobium monoxide crystal and/or diniobium mononitride crystal, a capacitor using the sintered body and the production method of the capacitor. A capacitor using the above described niobium sintered body has a large capacity per the unit weight, a good specific leakage current value and excellent high temperature property.

Abstract: A method to agglomerate metal particles such as tantalum and niobium powders is described which includes combining a volatilizable or vaporizable liquid with the particles to form wet particles; compacting the wet particles; drying the compacted wet particles to form a cake; and heat treating the cake to form the agglomerated particles. Also described are agglomerated particles obtained by this method and further, particles, preferably tantalum or niobium powder, having a flow rate of at least about 65 mg/sec and/or an improved pore size distribution, and/or a higher Scott Density. Capacitors made from tantalum powder and niobium powder are also described.

Abstract: A Mo—Cu composite powder is provided which is comprised of individual finite particles each having a copper phase and a molybdenum phase wherein the molybdenum phase substantially encapsulates the copper phase. The composite powder may be consolidated by conventional P/M techniques and sintered without copper bleedout according to the method described herein to produce Mo—Cu pseudoalloy articles having very good shape retention, a high sintered density, and a fine microstructure.

Abstract: The invention according to the present application provides a high strength solidification body by solidifying a starting metallic powder of iron and the like by means of plastic working using hydrostatic pressing, which is, for instance, a high strength high toughness steel material and the like having a superfine texture comprising a crystalline texture consisting of grains 5 &mgr;m or less in average diameter, or preferably, 3 &mgr;m or less in average diameter. Furthermore, the present invention provides a steel material included in the high strength solidification body, which contains oxide grain 0.2 &mgr;m or less in diameter at a volume ratio of from 0.5 to 60%.

Abstract: Metal powders are pressed into compacts more readily through the addition of a minor percentage of dimethyl sulfone binder. Dimethyl sulfone may be dry-blended with the metal powder by mixing it in the form of a powder, or it may be wet-blended by first dissolving it in a suitable solvent, then adding it to the metal powder and evaporating the solvent. Dimethyl sulfone may be almost completely removed from compacts pressed from tantalum, etc., either by vacuum distillation or by water leaching, to leave compacts uncontaminated by the binder and suitable for further processing into capacitor anodes, etc.

Abstract: A thin arc segment magnet made of a rare earth sintered magnet substantially comprising 28-33 weight % of R and 0.8-1.5 weight % of B, the balance being substantially Fe, wherein R is at least one rare earth element including Y, and T is Fe or Fe and Co, which has an oxygen content of 0.3 weight % or less, a density of 7.56 g/cm3 or more, a coercivity iHc of 1.1 MA/m (14 kOe) or more at room temperature, and an orientation Br/4&pgr;Imax of 96% or more in an anisotropy-providing direction at room temperature can be produced by using a slurry mixture formed by introducing fine alloy powder of the above composition into a mixture liquid comprising 99.7-99.99 parts by weight of a mineral oil, a synthetic oil or a vegetable oil and 0.01-0.3 parts by weight of a nonionic surfactant and/or an anionic surfactant.

Abstract: Disclosed is a sintered Ti-based material product derived from injection molding of a powder material. The outer layer region of the product comprises a lower amount of carbon than the inner layer region of the same. The inner layer region comprises a Ti-based carbide which has an average grain size of not less than 1 &mgr;m and which is dispersed in the inner structure to have an area fraction of not less than 0.1% to not more than 20%. The outer layer region comprises a lower amount of Ti-based carbide than the inner layer region. There can be observed an area fraction of less than 0.1% of the Ti-based carbide at the surface of the sintered Ti-based material product.

Abstract: A process for producing a ceramic-metal composite, includes (1) mixing TiO2, and optionally Ti, with at least one of a boron-containing or carbon-containing material to give a green body mix; (2) heat treating the green body mix to a temperature from 900° C. to 1900° C. and below a temperature which leads to an autocatalytic reaction; (3) carrying out an exchange reaction between the material and the TiO2 to give a reaction product comprising at least one of TiBx and TiCy, wherein 0≦x 23 2 and 0≦y≦1; (4) producing a porous green body from the reaction product; (5) filling the porous green body with liquid aluminum after the exchange reaction; and (6) carrying out a reaction between the reaction product in the green body and the aluminum to form the ceramic-metal composite comprising a ceramic phase selected from the group consisting of TiBx-, TiCy-, TiCN- and Al2O3 and a comprising a metallic phase comprising an intermetallic compound of Ti and Al.

Abstract: Disclosed is a molding method for powder particles, which is excellent in molding performance, and which makes it possible to obtain a preliminary molded product excellent in strength by enhancing mutual bonding between particles in the preliminary molded product. A molding apparatus for powder particles includes an outer frame die having a mold space with a lower punch and an upper punch to be slidably fitted thereto. Slight clearances exist between the outer frame die and the lower and upper punches. A mixture is prepared by mixing a powdery raw material with a liquid additive to cause an exothermic reaction therewith.

Abstract: The present invention discloses a tantalum powder for capacitors and a method for making said tantalum powder wherein agglomerated tantalum powder is produced by means of thermal agglomeration of starting tantalum powders in the presence of hydrogen.

Abstract: A process of consolidating tantalum metal powder to essentially random texture, and the product thereby produced.

Abstract: A sintered electrode of high-melting metal (for example tungsten) is produced from spherical metal powder having a well defined particle size. The mean particle size is from 5 to 70 &mgr;m. The particle size distribution covers a range from at most 20% below to at most 20% above the mean particle size.

Abstract: A method for forming dendritic metal powders, comprising the steps of: (1) heating a powder comprising non-dendritic particles, under conditions suitable for initial stage sintering, to form a lightly sintered material; and (2) breaking the lightly sintered material to form a powder comprising dendritic particles. In one embodiment, the lightly sintered material is broken by brushing the material through a screen. Another aspect of the present invention comprises the dendritic particles that are produced by the method described above. These particles can comprise any suitable metal, such as transition metals, rare earth metals, main group metals or metalloids or an alloy of two or more such metals. The particles can also comprise a ceramic material, such as a metal oxide. These particles are characterized by a dendritic, highly anisotropic, morphology arising from the fusion of substantially non-dendritic particles, and by a low apparent density relative to the substantially non-dendritic starting material.